This was a hat that I built for the Wicked Witch of The West in an Ohio Valley Summer Theater production of The Wizard of Oz. It consists of a foam board (strong stuff!) glued together with my favorite glue "Household Goop" (Cheap and super super strong!). It probably would have looked neater covered in fabric, but I thought the framework was just to pretty. This one has a copper wire framework that was custom shaped for the performer's head (this isn't necessary unless you plan on rolerblading like she had done). Foam board is just about the easiest stuff to work with. All you need is an Knife >:) and some idea of what shape you want it to be in. Cut what size and shape you want for the brim (wide brims are extra nice :) out of the board. To get the center hole for your head just right, get a small piece of bendy wire and wrap it around your head at the level you want the hat to sit. Hold its shape long enough to draw it out directly onto the foam board. Cut it out, now you have a brim! for the top part, you can roll (may be a bit unwieldy with 1/4 inch thick foam board) either a tube for a top hat, or make a frame work like the one above. I cut out the center tall portion first then glued some ribs on later. I held them in place with some pins long enough for the glue to dry.
I cheated a little on the hat in the picture to the left. I bought a real hat then extended the brim with foamboard. The end effect is a preacher hat look. People always seem to think I'm Jewish or someone foreign to the ways of America.
