How to Make Costume Hats

The hat is one of the most overlooked articles of clothing when costuming. Although in these days of climate-controlled buildings and automobiles it is fashionable to go bareheaded, in earlier times having no hat was as unthinkable as forgetting to wear pants. A hat served many purposes. Since about 90 percent of your body heat is lost through the top of your head, a hat served as insulation as well as protection from the elements. When creating costumes, consider the hat as an important finishing touch. Does this Spark an idea?

Things You'll Need

  • Hat fabric
  • Hat stiffener
  • Pattern
  • Sewing machine
  • Sturdy thread
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Instructions

    • 1

      Select a pattern. There are many good costuming patterns that incorporate hats. McCall's and Simplicity both have lines of costuming patterns that are dated to particular time periods and are authentic, or can be made so with few alterations. Most of these patterns include hats. There are even a few that are only hat patterns. More advanced tailors may wish to freehand their own patterns.

    • 2

      Select your material. Many patterns recommend a specific material. However, not all materials that are commercially available today or are recommended by the pattern maker are authentic. A little bit of research will provide you with a list of fabrics that were widely used in the period that you wish to costume for. Stay away from synthetic fibers. Instead choose buckram, felt, straw or wire frames for stiffening, and natural fibers---including linen, cotton and silk---for covering.

    • 3

      Take a test run. Before cutting and assembling your hat, try out the pattern using lower-grade materials first. This will help you to avoid making mistakes while working with more expensive fabrics.

    • 4

      Wear your test hat. Some hat designs, then as now, were meant to impress rather than to be comfortable. Wearing a hat for a period of time will help you determine if it is comfortable or if you need to make modifications.

    • 5

      Assemble your final hat based on pattern instructions.

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