Step 1: Supplies & Getting Ready
A pair of Scissors and a knife
A roll of Tin Foil
a Marker (Washable, and very light color
Make your workspace clear and free of things such as lint or eraser bits. You will need some room. Set down a thing of newspapers so that you don't cut your surface or anything.
Don't cut yourself. Ever. EVAR! Simple enough. If you cut your finger off, it's your own fault.
Step 2: Casting the Top of the Hat
Note: Using tin foil and making a cast of a hat can save you the trouble of putting duct tape inside the hat to try to make a hat inside the hat. This works for any hat. It also doesn't make you look cheap by just duct taping the hat completly. That's called cheating.
Step 3: Duct Taping the top of the Hat
Coming from experience, if you've made sheets of Duct Tape, you've probably made one sticky sheet, and then another, and tried to put the two sheets of paper together. I don't recommend this. Instead, make one sheet, and while sticky side up, start placing strips sticky side down peice by peice along the sticky sheet. This will save time and frustration.
Now, flatten the tin foil 'Cranium' on the sheet, making sure to keep the same shape.
When you've got it to the desired shape, outline using a marker or pen (Trust me, use marker) the shape, and when your done, cut out the shape of your 'cranium'.
Make sure to cut just a little outside of your outline, so that the shape will be sure to stay the same. Now wipe off the outline. Glad you used marker, huh?
Step 4: Making the Sides of your Duct Tape Hat
My hat was divided into two, so that's how I worked with it. I did one side of the hat, and then the other.
After you make your cast, then follow step three; Sheet, Then cut. You can skip the outlining part, since you'll most likely have a rectangular shaped piece.
Now tape the sides together at one point. Leave the other so you can measure and stuff.
Wrap the side's around your head. If it doesn't fit, just add a small sheet of duct tape, and you'll be good.
The peice wraps around weirdly, doesn't it? Makes a strange 'V' shape or something, and isn't perfect? Well, that's alright; while holding the peices (Let it loose a little bit so when you wear your hat it actually fits) just tape it up, and cut off the peices that don't fit. Easy peazy, lemon squeezy.
Step 5: Putting the top and sides togeter
I highly recommend using small strips of Duct tape. It will be nigh impossible to put one long strip on there without making more of a mess than needed.
Step 6: Making the Brim
-Lay out a sheet of tin foil. Make sure that it's larger than your actual hat.
-Cut the edges so that the brim is circular.
-Start putting small strips (Recommended) of tape sticky side down on the tin foil, going in a nice circular pattern. Start with the edges, and go in.
-Stop when the duct tape starts going into the area where the top of the hat would go in.
-Repeat the process on the other side.
-When done, duct tape the edge, so that you don't somehow cut yourself.
-Put the top of the hat on the brim, and using a washable marker, or some other marker like device, outline the hat.
Now, take the top of the hat off.
-Start cutting just a little bit inside by using a knife. Be sure to go in a circular or oval pattern.
-if the knife didn't go all the way thru, use scissors to cut those pesky little annoying areas.
The reason I keep the tinfoil in between the peices of duct tape is so that there's a little bit of support in the brim. I really don't like the brim of my hat flopping around, and I doubt you like it too.
Step 7: Finishing Up
I spent a little under 3 hours making this, but that's only because other stuff was happening, but hey.
I'll make another, much better looking hat sometime in the future. Right now I'm working on another project, Duct Tape Armor. Don't ask, it will probably be an instructable, depends on if I have time. Anyways, hope you have as much fun making a hat as I did. And don't forget to comment or rate my creation. Thanks a bunch, and also, if you have anything that I should add, or could have done better, just tell me.