Created my steampunk hat out of an old exercise mat. I wore this to an event at the Renaissance Faire, April of this year. This is how you can create your own hat. There is also a link on my website, happychanceshop.com that explains how to do it.
You will need the following supplies:
* Exercise foam mat (I purchased mine at Walmart a long time ago ) Do not buy craft foam that is very porous. It will not hold the glue or paint well.
* 1 Thin craft foam (purchase at JoAnn or Michaels)
* Strong bonding glue or hot glue
* Make your pattern or buy my pattern on my Etsy store
* Acrylic paint
* 16" thin elastic
* Decorations
* Hole puncher * Scissors
This is my basic pattern you can use to draft your own and make changes as you wish. I will also sell this on my Etsy site for $3 should you choose to just buy my pattern.
Once you've cut your pattern, you are ready to glue the items together. I've tried all the glues recommended on-line and so far none have worked except hot glue.
Step 1) Glue the crown on the brim first. Pinch it down like you are making a pie crust so it welds together. Let it dry then glue the round top on top of the brim and let that dry. When you are done, you should end up with a product like this. (see unfinished photo of hat)
Step 2) Cut Out Drills and Bits
Take your hole puncher and punch out a few bits (about 6 of them) from the thin craft foam. Cut 3 of the arrow looking piece from the thin craft foam also. This pattern will be available on my Etsy site if you purchase my template. Otherwise, you can easily create your own by drawing a fat arrow. These will be glued on your hat.
Glue the drill bits on the arrow as shown on the photo. After it dries, glue each piece to each side and one on the back of the hat.
Step 3) Using acrylic paint, paint the inside first then let it dry before painting the outside. It should take a day or 2 to dry.
Step 4) After it dries, cut 2 small square pieces and cut 16" of 1/4" or 1/2" elastic. Turn your hat upside down. On each end, you will glue the elastic and foam square on each side of your hat. This will function as a way to put your hat on.
Step 5) Once the glue is dry, you are ready to decorate your hat. Try to keep the decorations light. I used a lot of hot glue on mine.
Step 6) When it's done, take a photo and show it off to the world! You can view more by clicking here.