This looks like a good day to try an idea I've been mulling over for a duct tape hat to wear at the town's parade on July 4th!
2-Liter soda bottle
Rolls of Duct Tape (1 each of Silver, Red, White, Blue)
A hat to copy (I worked with a military-style cap)
The first part of the project is to develop patterns from the hat. The military-style cap I chose is simple - basically a low cylinder made from a strip of material, an oval top and a short bill.
Start by tracing the brim onto the cardboard. If you don't have your own hat to copy, print out the pictures that I posted in this instructable to make your own pattern (that's why I labelled them with their dimensions and photographed everything on a 1"X1" grid).
The dimensions I used for the oval top of the hat and the two side pieces are labelled in the third picture on this page...
Step 1: Sheets of Silver Duct Tape
The silver duct tape will be the inside lining of your hat.
Trace the top of the hat unto the smaller piece of sheet. Notice the notches. They are there to identify the longest dimension of the oval and help you orient it when you attach it to the side of the hat.
When you lay out the two side pieces, make sure that they are mirror images of each other.
Trace the bill pattern onto the side of a 2 Liter soda bottle with your marker and cut it out.
You'll cover the top of the plastic bill (convex side) with blue duct tape. Neatness counts!