How to Make a Foam Sombrero Hat. The sombrero hat is a Hispanic cultural icon, and is an important part of the traditional Mexican hat dance. This wide-brim hat is usually made of straw or felt. You can use craft foam to make a hat you can wear to a Cinco de Mayo party or as part of a Halloween costume.
Things You'll Need
3 sheets 10 inch by 13 inch craft foam
Hot glue gun
Roll the foam craft sheet into a large cone shape and hot glue it together. Trim off any excess foam from the bottom and tuck the extra foam on top into the cone's center.
Lay two more 10-inch by 13-inch foam craft sheets side by side. Place the large end of the cone in the middle of the sheets at the edges and trace it. Set the cone aside and you should see a half circle drawn on each sheet.
Draw another big circle around the traced circle from Step 2 to make the hat's brim. Take the two foam sheets apart and cut along your trace lines.
Cut two 4-inch thin strips from the scrap foam to help connect the large donut shape together with hot glue. Cut 1-inch slits along the bottom of the cone an inch apart and fold the slits down for a place to glue the brim.
Put hot glue on each slit quickly placing a part of the donut shape on a slit to attach the brim. Cut a 1-inch craft foam strip and glue it to the brim to become the hat strap.
Tie the ribbon at the top of the sombrero and glue in place. Then glue a pom-pom to each end of the ribbon.
Take the pinking shears, cut triangles out of craft foam and cut five to six 1-inch slits in the hat brim. Glue one side of each slit to curve into an upward brim and glue the triangles around the outside of the brim.
Use a variety of colored craft foam for a more decorative hat.