How to Make a Cowboy Hat With an Empty Beer Box

A cowboy hat fashioned from a beer box requires little expense and time.

Turning a beer box into a cowboy hat demonstrates a certain level of creativity when carrying out this craft. Beer boxes are made of durable cardboard that is easily molded into a hat form. This type of cowboy hat will provide a costume accessory for the cowboy in the house, whether it be for Halloween or just everyday pretend play. Paint the finished product in a color that matches the cowboy's personality and you are all set to gallop off into the sunset.

Things You'll Need

• Scissors
• Tape measure
• Stapler
• Batting helmet
• Transparent tape
• Duct tape

Instructions

1. Unfold the beer box into one long piece of cardboard. Cut a strip of cardboard, approximately 2 inches by 14 inches, from the side panel of the beer box. Wrap this strip around the wearer's head. Staple the strip where the two ends meet. This will serve as the inner ring of your cowboy hat.

2. Lay your batting helmet on the work surface. Cut out pieces of cardboard from the beer box. Wrap them around the batter's helmet to make a hat form. Use tape to connect the pieces. Use duct tape to reinforce this tape. You will now have a hat form for the top of your cowboy's hat. Remove the batter's helmet from underneath. Staple the ring to the inside of the form. Cover the inside with duct tape so the finish is smooth for wearing.

3. Use one of the remaining pieces of cardboard to make a rim around the hat form. Place the hat form on the cardboard and trace around it. Use your tape measure to measure 3 inches around the entire form. Make a circle that is 3 inches from the original tracing. You now have a ring that is 3 inches all the way around the perimeter of your hat. Cut out this ring. Staple this ring to the bottom of the hat form.

4. Cover the entire hat form and ring with strips of duct tape for a smooth finish. Bend the top of the hat form inward before placing the duct tape on. Place the duct tape in the crease of the top to hold the hat's shape.

Tips & Warnings

• Choose duct tape in a color to add pizzazz to the cowboy hat.

• Place a star on the center of the hat for an extra touch.

• Make sure all staples are covered with duct tape to prevent scratching the wearer.

References

• Free Patents Online: Hat Made From Beverage Container