Puff Embroidery Flat Brimmed Hat

Step 4 Some Tricky Parts

The trickiest part I encounter was the ears.  There was no good way to cover them. Since there have 3 sides (the outside, inside the forehead circle, and inside the eyes).  The "three sided" nature of the shape made it hard to figure out how to cover everything, and not leave little triangles where the forehead met the ear.  My test piece was helpful here because what I thought was good on paper, turned out to not be very good at all.  At first I tried to have some stitches go from top to bottom, and cover them with some going from left to right, but the stark contrast looked bad.  I also played with having some threads disappear down in the middle of the ear, but this bunched up the  other threads causing gaps.  I ended up doing an alternating weave which covers the entire area, and also provides good edge covering and looks slick enough that the different thread directions don't stand out horribly.