This project was the result of really wanting to use the spiked studs I had. It could be part of a future villainous costume, but for now, I just had fun taking photos with it.
Step 1: Materials
thin veg tanned leather
thin colored leather
spiked studs (You could make a more traditional eyepatch without these.)
philips screwdriver (for tightening studs)
nesting objects (I used some Russian nesting doll measuring cups.)
sheet of paper
quick dry tacky glue
Step 2: Forming the Patch
Create a paper template by drawing it or using one from the web, like this one. Cut it out and make sure it fits your eye well. It should be a bit bigger than you'd like as it will be curved when transferred to leather.
Trace the template onto the leather and cut it out.
Wet the leather and press between a towel to get as much moisture out as possible.
Set the leather in the center of the smaller nested object and press the larger object over it. Press firmly. (If you're using the measuring cups, I used the two largest head pieces.)
Remove the top nested object, and allow to dry.
Step 3: Colored Leather
Cut a section of colored leather that is about 2/3" larger than the patch.
Apply a thin layer of quick dry tacky glue to the front of the patch and apply the colored leather.
Press firmly around the front of the patch to wrap the colored leather smoothly around it until it begins to dry.
Trim the colored leather to about .5" around the patch.
Apply a small amount of glue to the edge of the veg tanned patch and the edge of the colored leather.
Wrap the edge of the colored leather around the patch and press firmly until it begins to stick.
Press the patch in the nested objects once more.
Allow to dry.
Step 4: Spikes
Draw radiating lines from the center of the patch.
Use a leather punch to put a hole at the center.
Apply a spiked stud to the hole.
Punch the next hole on one of the radiating lines far enough away from the first stud that there is enough room for the next stud.
Step 5: Repeat
Repeat the process of punching a hole and applying a stud until you've covered the whole patch.
Step 6: Strap
Cut two thin strips of colored leather for the strap and rivet one to each side of the patch.
Wrap the straps around your head and cut them to a length that is 4"- 6" shorter than necessary to wrap all the way round your head.
Rivet a piece of elastic, attaching the two straps, to make up the difference. This will allow the patch to fit snuggly.