Custom Cow Boy Hat for Plushies

One day, I was looking at Tigger and Barney, and it looked like they needed a hat to protect them from the sunlight. So I decided to make this hat for them, and it fits most plushies, since their heads are compressible and allow for a perfect fit that prevents the hat from falling off.

1. Caliper
2. Felt
3. Scissors
4. Sewing Machine/Needle and Thread

First, I took measurements of Tigger's and Barney's heads to approximate the diameter of the bottom of the hat. To do this, I used a caliper. While this method of measuring does give an imprecise dimension, it is a good enough approximation to guide the rest of the scale for the hat to make it look proportional and to fit on their heads.

Tigger's head was about 3.45 inches, and Barney's head was about 2.29 inches. So the diameter of the hat should be between 2 inches and 3 inches to fit on their heads. I went with halfway in between, and used 2.5 inches for the diameter of the hat because Tigger's head can be compressed to fit the 2.5 inches, and Barney's head could be pushed into the hat at an angle to ensure a proper fit.

Then, I made a sketch of what I wanted the hat to look like. I went with a simple design of a flat cowboy hat. I also added dimensions to it to help me figure out the scale of the hat. Since the hole in the hat needed to be about 2.5 inches to fit both Tigger and Barney's heads, I went with a 2-inch rise for the top part of the hat. I did this because it seemed proportional.

Once I finalized the vision I had for this cowboy hat to protect Tigger and Barney's heads from the summer sun, I began to create a paper prototype. I decided to start with a paper prototype instead of directly going to start the final hat because it will allow me to save material and help me understand the creation process before beginning the actual hat, which will prevent mistakes on the final hat.

The first step was to create the brim of the hat. I sketched the 2.5-inch diameter circle first, then sketched out a brim that looks porportional to the circle and would help protect Tigger and Barney from the sun.

To create the 2-inch rise for the top of the hat, I cut out a 2-inch by 8.5-inch rectangle from a piece of paper, with some extra room on the top to attach to the brim. I plan to roll this rectangle into a cylinder and insert it into the hole in the brim.

Next, I attached the top of the hat to the brim by rolling the rectangle I cut in step 4 into a cylinder. I also cut slits into the extra space in the rectangle to allow me to fold it onto the brim and attach it using tape. Additionally, everything that is taped in this prototype will be sewn together in the final product.

I then cut out a 2.5-inch diameter circle and taped it to the top of the hat to cover the open space. I came to the realization that it sort of looked like a top hat, which was not the goal. So, I crushed the top of the hat in rage and frustration because I failed. Just kidding. I crushed it to make the paper less rigid and more flexible like the felt I will be using for the final product.

Now it's time for Tigger and Barney to try on the paper prototype! Barney's head perfectly fit into the hat, while Tigger's head was a bit of a squeeze to get on. However, this is not a concern because the final product will be made out of felt, which is a stronger material than paper and will allow for Tigger's head to be squeezed into the hat; effectively preventing it from falling off.

At this point, I also realized that the sides of the brim could be folded up to the middle to make it look more like a folded cowboy hat, as pictured above. This makes the hat more versatile and could be made as an alternating feature by place velcro or magnets.

To create the final product out of felt, I followed the exact same steps as from the paper prototype. I also used the paper prototype as a guide to scale the final product. Additionally, I added some final touches to the final product that were not on the prototype, such as a black band around the cylinder and some leaves to make it look better. The black band is made out of fabric, and the leaves are made out of green and red felt.

As seen in the pictures above, the final product was very similar to the prototype but it looks more like a cowboy hat due to its color and material.

Now it's time for the moment we've all been waiting for. Tigger and Barney trying on their new hat. Yes, there is only one right now, so they will have to share... Though one could wear the prototype. Not only does the cowboy hat protect Tigger and Barney from the sun, but it can also have two appearances as shown in the pictures; it can be a flat cowboy hat or a folded cowboy hat.

Overall, this was a fun process, and now Tigger and Barney have a hat to enjoy. I hope you guys liked these instructions, and they help you build a hat for your little friends.