This instructable will mainly describe how to make the rooster hat. The Robot Chicken hat is made exactly the same way just with a different beak and with some tin-foil adornment. I will also show a couple of the other very simple extra pieces I made. The Robot Chicken costume in its entirety took about 5 or 6 hours to make (exclusive of purchasing the materials).
Step 1: Gather Your Ingredients
Felt - yellow, white, red, black. I used mainly stiff felt produced by Eco-Felt. I think you could use soft felt for the hat, but the beak and the comb need to be stiff. The felt comes in roughly 8.5 x 11 sheets of which you will need 2 sheets to make the hat, 1 for the comb, and one for the beak. Each sheet of stiff felt should be somewhere around 75 cents. Soft felt will be cheaper.
Needle and Thread - regular and/or embroidery thread in a variety of colors that match the felt.
Scissors, glue gun, scrap paper, something red and possibly sparkly
Step 2: Make the Beak and Comb
1. Draw a comb that you like the shape of.
2. Cut it out of felt.
The beak is slightly more complicated, as it requires sewing.
1. Draw a beak shape you like
2. Cut it out of felt
3. Sew together the front of the beak so that it is bent in half (beak shaped).
Step 3: Put Together the Hat Base
1. Cut six rounded triangles of the same size and shape as makes up your baseball cap.
2. Pin two of the triangles together. Since the sides are rounded, the pieces should curl into a head-shape. Again, I used stiff felt, which will cause the hat base to be firm and stand up by itself.
3. Sew together two groups of three triangles. that will cover each half of your head.
4. When you put the two halves together, insert the comb in between them so you are sewing through three pieces of felt: the comb, the left side of the hat, and the right side of the hat.
Step 4: Attach the Beak and Eyes, Etc.
If you're making Robot Chicken rather than just a regular rooster, now's the time you'd also make the robot half of the face. I just free-formed it out of tin foil, the bottom of a water bottle, and a red sparkly hors d'oeurve skewer thingy that I picked up one year on a whim and have never used. It doesn't matter what you use here as long as it's red (as it's a laser eye). I attached it all with a hot glue gun.
Step 5: Make the Rest of the Costume.
I'm not showing the steps, again, because it was just kind of an ad hoc throwing/crumpling together of aluminum foil, newspaper, and hot glue gun.