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Uzbeki Spy Hat (or Wizard Hat)

Step 5Attach crown and brim

Attach crown and brim
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  • hatToBrim2.jpg
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This is the only slightly difficult part. You now have a cone whose lower edge is length X, and a stuffed doughnut shape whose circumference (taking into account the folding that occurs on the inner sides) is Y. Y is bigger than X and yet they must be sewn together. Enter the concept that we in the Uzbeki spy hat industry call, 'ease': just mush it together and make it fit. Here's how.

Using pins or a marker, or paper clips, or any method, really, mark 4 equidistant points on the lower edge of the hat - quarter it. Similarly, mark 4 quarters on the seam allowance sticking out of the doughnut brim. You can do this by measuring, but it's fine to do it by just flattening the pieces to get halves, and then bringing the halves together and flattening the other way to get quarters.

Now place the cone through the doughnut and pin the two together, matching up each of the quarter markings. Match the stitching line on the doughnut up to a bit below the end of the interfacing on the cone. You can pin at the eighths, as well, if you want. Sew the pieces together, smushing the extra length up to fit the shorter length. This is a bit tricky to sew as the hat is fairly stiff and wants to come out from under the needle. Just go slow and reposition the hat as needed. It isn't all that long of a seam, after all.
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I'm a founding member of Noisebridge (https://noisebridge.net), a hackerspace in San Francisco, and Ace Monster Toys (http://acemonstertoys.org/), in Oakland. If you're in the area, stop by and say h...
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