Things You'll Need
One 12 can cardboard beer box
One 24 can cardboard beer box
Hat (baseball or fitted)
Glue stick or rubber cement
Clear packing tape
One of the craziest (and most popular) upcycling craft projects on the Internet right now is the "Beer Box Cowboy Hat". This project takes two cardboard beer cases (a 12 pack and 24 pack, respectively) and turns it into a funky chapeau that is definitely a conversation starter. Whether you wear it as part of a cowboy costume at Halloween, or at your next keg party - you're sure to be the topic of conversation when donning this DIY hat. Not to mention, you're doing your part for the environment by recycling old beer cartons!
Create the crown of the hat. Take the 12 can beer box and turn it onto the narrow end. Measure 4 1/2 inches up from the bottom and mark on all four sides. Draw a line around the box and then poke a hole to make a starting point to cut from. Cut all the way around the four sides of the box, on the line. Discard the top portion of the box and keep the 4 1/2 inch portion as the crown of the hat. Measure one inch intervals all the way around the cut bottom of the crown. On each of those marks, cut a one inch slit. Bend those tabs out to complete the crown.
Make the brim of your hat. Cut the ends off of the 24 can beer box. Then cut along one of the long edges of the box. Fold the box in half at the center and flatten with your hands. Place the hat that you wear in the center of the flattened box halves and trace around it with the marker. Cut through both layers of the box with the craft knife. This makes the opening for your head and where the crown will attach to the hat.
Draw an approximate shape for the brim (a large oval works well) and cut away the excess box. Separate the two brim pieces. On the bottom of the top brim piece, paint rubber cement or cover with glue from a glue stick.
Push the crown of the hat through the opening of the top brim piece and press the tabs you created onto the gluey surface. Flip the hat over and add another thin layer of glue or rubber cement, then place the bottom brim piece (with the logo facing out) onto the hat. Press the brim pieces together to seal the hat into place. Allow the glue to dry fully before proceeding to the next step.
Shape and trim the hat brim in the fashion of a cowboy hat. Tape the edges together with clear packing tape. You can also reinforce the inside of the hat and the joints of where the hat crown meets the brim with packing tape if you so desire. Wear and cause a cowboy commotion wherever you go.
If you want to create a realistic cowboy hat you can spray paint this project after it's completed.