Introduction: How to Make a Duct Tape Hat

How to create a Duct Tape hat out of, you guessed it, Duct Tape! Using only Duct Tape, Tin Foil, Scissors, X-acto blade or knife, a marker, and a hat, you too can have a hat made out of that wonderful product, Duct Tape!

Step 1: Supplies & Getting Ready

Supplies that you will need include:
Duct Tape
A Hat
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

To make the Top of the hat, instert some Tin Foil into the hat, and put the hat on, making sure to flatten the tin foil so that it will make the shape you want. Be sure that you are doing the TOP of the hat, tip of the hat, whatever you want to call it. Then, take the tin foil out of the hat. You should now have a cast of the top of your 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

Now you'll make a sheet of Duct Tape, making sure it's relativly the same size of the cast. Make one side, and then the other. To make a sheet, place one strip of duct tape sticky side up, and then place another strip of equal length halfway down, also sticky side up, halfway down the first strip of DT. When you have the size you want, start on the next side.

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

Using the same method you used to make the top of your hat, you'll make the sides of your hat. NOTE: THIS IS NOT THE BRIM OF THE 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

Just a simple job of duct taping the top of the hat to the sides. Shouldn't be too hard.

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

This part is a lot easier than the others. Making the Brim of the hat. To do this, just;

-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

Now just duct tape the brim to the top of the hat, and there ya go! Your own super cool duct tape hat. Mine turned out more like a cowboy style, than bucket style like the original hat. I'm sure you can do better, in fact, I'd like to see your hat, if you decide to make one. Just post it in the comments.
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.

Alrighty Then.


pyromaniac123456789 made it!(author)2013-10-20

Why would you use a hat to make a hat?

y2leon made it!(author)2011-08-08

Nice job, now I can wrap it up with some cheap faux leather and... LISTO!

armorlord made it!(author)2011-04-27

Pretty nice hat... But the design can be improved... how about using different colored tape for stylish designs?

I also found this website, , that sells awesome duct tape products.. You've never seen anything like this, check them out!

lucek made it!(author)2010-01-16

a store round here sells 24"X24" duck tape patches. could be a better starting material.

kibbler made it!(author)2010-09-01

Wow really??? where???

lucek made it!(author)2010-09-01

if you know ocean state job lot that's where I've seen it.

instrct made it!(author)2010-08-16

nice tutorial. how long did it take tyou to make these? how many rolls? btw i found a similar thing on

lobo_pal made it!(author)2008-12-15

Two things, one there is a really good pic. sequence for making a duct tape sheet on the duct tape book cover instructable. Second, besides looking cool, yes I think duct tape hats are cool, why would you need a duct tape hat if you have a hat already?

Wills42 made it!(author)2008-12-23

Well you see... um.. herm... uh, yeah... ur.... LOOK BEHIND YOU! *Run away*

lobo_pal made it!(author)2008-12-23

*Chase down* *Tie with duct tape from hat*

cornflaker made it!(author)2009-01-05

Haha *Pokes duct taped Wills42 with a pointy stick* :P

lobo_pal made it!(author)2009-01-05

Just poking, where's your duct tape spirit.

cornflaker made it!(author)2009-01-07

Its... Uh... LOOK HES GETTING AWAY! *Duct tapes lobo_pal to Wills42*


*Pokes some more*

lobo_pal made it!(author)2009-01-07

*Uses telekinesis to throw cornflaker into the wall, and free himself. Keeps hitting against the wall with mind power*

cornflaker made it!(author)2009-01-09

*Uses pyrokinesis to thwart lobo_pal's plan, accidently melts all of the duct tape... :(* *Pokes some more with now burning stick*

lobo_pal made it!(author)2009-01-09

*Uses cryokinesis to stop the fire and freeze everyone else in the room. Pokes with stick and accidentally shatters them, oops*

cornflaker made it!(author)2009-01-14

*Remains un-shattered waiting for the lobo_pal's cryokinesis outburst to end hoping he forgets to poke me* *Wonders if lobo_pal will use his new ability to bring the duct tape back*

lobo_pal made it!(author)2009-01-14

*Wraps cornflaker in duct tape to make a full body cast, then keeps wrapping until it is a duct tape coffin. Then buries cornflake.

cornflaker made it!(author)2009-01-15

*Reluctantly uses pyrokinesis again to completely melt the duct tape coffin, then realises lobopal was using cryokinesis not chronokinesis...* *Uses chronokinesis to go back before lobo_pal gets away... Grabs a bigger stick on the way...*

lobo_pal made it!(author)2009-01-15

*Unfortunately doesn't realize that chronokinesis ripped the dimension, and caused a black hole to appear near Earth, everyone dies.*

cornflaker made it!(author)2009-01-16

*A piece of duct tape blocks the black hole and prevents the rest of the universe from being sucked in... Hurray For Duct Tape! :D ... Hmm you know this white nothingness isn't tooo bad...*

s8erdude made it!(author)2009-05-17

KILLS EVERYONE!!!!!!!!!!!!!!

lobo_pal made it!(author)2009-05-17

No. You just killed it. Sorry everyone, this guy just killed the fun.

s8erdude made it!(author)2009-05-18


toogers made it!(author)2010-01-01

shouldn't have interceded. lame.

lobo_pal made it!(author)2009-05-18

Too late, he killed himself because you're so lame! He's dead! He couldn't live in a world with people like you!

lobo_pal made it!(author)2009-01-16

So, want to play I spy?

cornflaker made it!(author)2009-01-18

Ok, Ill go first, uh its white... Very white...

lobo_pal made it!(author)2009-01-18

That pale kid in the corner eating paste?

Xerillum made it!(author)2009-01-20

That's me!

lobo_pal made it!(author)2009-01-20

I think I've gone blind.

cornflaker made it!(author)2009-01-21

Haven't we all lol

lobo_pal made it!(author)2009-01-21

Who said that?!

cornflaker made it!(author)2009-01-22

Me :P haha I just thought it sounded smart lol

lobo_pal made it!(author)2009-01-22

I can't see you, duh.

cornflaker made it!(author)2009-03-31

Haha I just realized what you meant lol

Moomoomilk made it!(author)2009-05-25

don't question it, just love it peace out homies

sharlston made it!(author)2009-08-04

tats cool what about black then it would look cool as hell :)

shabalaba made it!(author)2009-09-22

im prreetty sure hell isnt cool................dunce bucket

toogers made it!(author)2010-01-01

wow that's what i was going to say.

wizerd+745 made it!(author)2009-09-13

It's based off of a boonie but doesn't look anything like one...

sharlston made it!(author)2009-08-07

woaa thats well good,neat design -sharlston

prestonm made it!(author)2009-05-23

airzooka?!?!?ha ha good memories.....

Soylent_Green_Muffins made it!(author)2009-04-29

I "made" a hat similar to this with a cardboard New Year's hat. I re-sized it to fit my head more comfortably, and made a design out of the tape. Over the year and a half I've had it, I've been adding stuff to it. It now has a face and a light up bow tie on it. I wish I had a camera so I could upload a picture.

Joho+The+Hobo made it!(author)2009-04-10

Nice hat. I'm wearing mine now. :)
Had to delay making it half way through because i ran out of tape. Cheap Poundworld duct tape comes on really tiny rolls.

xuinkrbin. made it!(author)2009-02-19

Any thoughts on how to make a duct tape whip to go with it? That would be awesome!

kibbler made it!(author)2009-03-17

Whipping is my specialty. (inside joke with thedude123) Anyway, Just take about a 5 foot long piece of duct tape, and fold it. Then take it and twist it, then more tape. I can't explain it, I'll make an I'ble.

xuinkrbin. made it!(author)2009-03-18

Thanks! I look forward to it!

DuctTape+Pwnage made it!(author)2009-01-28

I made one of these for Live action role playing, and i was able to fit 9 throwing daggers, a small grapnel, and 4 packs of gum in there. Also got in a "wand" and a belt that slid out of the part where my head went, it was used to tighten it on. It looked just a bit bigger than this.

Brother_D made it!(author)2009-03-16


About This Instructable




Bio: I'm a graphic designer, and webcomic artist and writer.
More by Wills42:How to make a Duct Tape HelmetHow to make a Duct Tape Hat
Add instructable to: