How to Make a Chef's Hat for Halloween

It takes a chef's hat to complete a chef's costume for Halloween. The following instructions will work for an adult or child's costume. The dimensions used will depend on the measurements taken from the person who will be wearing the costume. The hat has two parts, the stove pipe section made from white cardboard, and the fabric balloon-like shape that protrudes from the top of the hat. The stove pipe section can be covered with white fabric, for a more finished look, or leave the white cardboard uncovered for a simpler project.

Things You'll Need

• White cardboard
• Measuring tape
• Clear shipping tape
• White sheet or muslin fabric
• Needle and thread
• Scissors
• Elastic
• Small safety pin
• Glue

Instructions

1. 

   Measure the circumference around the forehead of the person who will be wearing the chef's hat. Call that Measurement A.

2. 

   Cut a piece of elastic that is the length of Measurement A plus 1 inch. Cut a piece of cardboard that is a rectangular shape. Make two parallel sides of the cardboard the same measurement as Measurement A. The other two sides should be cut according to how tall you want the hat.

3. 

   Roll the hat to create a cylinder. The ends that are cut to Measurement A should be the top and bottom circular ends of the cylinder.

4. 

   Secure the sides, using clear shipping tape. This will be the stovepipe portion of the chef's had. Check to make sure the stovepipe fits onto the head before securing with tape.

5. 

   Measure the diameter of the stovepipe. This will be Measurement B.

6. 

   Cut a circular piece of white fabric. The diameter of this should be three times that of Measurement B.

7. 

   Sew a hem around the circumference of the fabric circle, for the elastic to be inserted. Fasten a small safety pen onto the end of the elastic, and thread the elastic through the hem. After the elastic goes all around the circumference of the hem, sew the two ends of the elastic together.

8. 

   Pull the fabric over the stovepipe, to fashion the hat. For a chef's hat with a droopy top, slip over the edge and do not pull far down the stovepipe. For a chef's hat where the fabric stands up, pull down over the stovepipe, so that the cardboard pushes the fabric up. Glue in place.