Download the template from the stats tab above. Trace the template onto your cardboard and cut it out.
You will need a lot of small pieces of duct tape for this project. It is best if you prepare them before you begin assembling the hat. Lay a strip of tape on your work surface and cut it into 1/2" pieces. You will need at least 50 of these pieces.
Begin covering your cardboard cut out with the small pieces of tape. Start at the point of the cut out. Wrap the piece around the point at a slight angle until covered.
Once the points are wrapped begin putting the small pieces along each edge of the cardboard. Fold the tape onto the back side.
Continue in this manner until the entire edge, front and back, is covered in tape.
For the next step we will make a double sided sticker. Start with a piece of tape 20" in length. Lay 10" of the tape on the parchment paper. Lay a second piece on the parchment, overlapping by 1/2 inch.
Lay four strips of tape on the parchment paper in this same manner.
Carefully lift up the parchment and fold the remaining tape onto the other side. You will now have two layers of tape sandwiching the parchment paper. Lay the template on top.
Trace the shape of the template onto the sticker and cut it out.
Attach the brim to your hat band using a few small pieces of tape. Begin on the outside.
Flip the hat over and using some small pieces of tape attach the underside of the brim to the hat band.
Once completed, the underside should look like this.
Do the same thing on the front of the hat.
Peel the double sided sticker apart and attach one sticker on the top of the brim.
Attach the other sticker on the underside of the brim. This will seal the edges and give your brim a clean look. Stay tuned for Part 3 where we will finish the hat.