The DIY Duct Tape Cap is a very cost efficient and fun project for anyone to do. Also just a word of advice for this project. You may want to use your head or even a manikin at times to model the hat as it progresses to make sure that it will fit properly.
Step 1: Materials and Tools
Here is a list of all of the materials you're going to use:
- 1x Duct Tape: No brand in particular
- Cardboard: Not a whole lot needed, just enough to cut out the visor
- Compass (optional)
- Hat/Ball cap to trace out the visor on the cardboard
Step 2: Constructing the Frame
Start by cutting a piece of tape long enough to fit around your head and stick the two ends together, forming a circle that fits on your head like a crown or a tiara. (Make sure that the sticky side of the tape is facing out). Next, cut a piece of tape that runs over the top of your head and stick the two ends to the sticky side of the circle, creating a semi-circle running across the center of the circle (Make sure that the sticky side of the tape is facing upwards). Finally, cut another piece of tape like before, however, place it perpendicular to the former piece of tape (sticky side up) forming a cross at the center of the circle .
Step 3: Construct Lid
After the frame is completed, your next step is to finish the lid.
Start by cutting strips of tape to extend from the outer edge of the circle to the center point of the cross section. Stick one side of the tape to the outer edge of the circle, and the other end to the center (sticky side up). Next, add another strip right next to the other with the strips overlapping partially on the edges. Keep repeating until the lid is completely enclosed.
Step 4: Constructing the Visor
To construct the Visor, begin by taking the cardboard and tracing the outer edge of a hat visor. Make sure that the visor is pressed flat onto your work surface when you trace the visor outline. This should leave a semicircle on the cardboard. Once the rim of the visor is traced, use the ruler to measure the distance from the edge of the visor to where the visor meets the rest of the cap. For the hat I was using, the distance was 2 3/4". After you measure the distance, remove the hat from the cardboard and mark the distance from the outer edge of the semicircle to the inside of the semicircle. Once the inside of the semi-circle is marked, use the compass to draw a semicircle inside the semicircle. The finished product should look like a crescent moon. After you finish outlining the visor, cut it out, and bend it in half so that it will conform to your head.
Step 5: Attaching Your Visor
After you've constructed the visor, the next step is to attach it.
To attach the visor, place it along the side of the lid where you want to be the front. Once placed, secure it with a strip of tape. after it is secured, tape the outside edge of the visor and cut vertical slits along the edge of the hat where the visor meets the lid and bend the newly created mini-strips outwards towards the visor.
After the visor is secured, place strips of tape to cover the visor and reinforce the structure. After the visor is completely taped, use the scissors to trim the edges and the corners of the tape on the visor to make it look better and help it to conform to the shape.
Step 6: Final Touch-up
The structure of the hat is pretty much finished; all that remains to be done is to tape off the outside of the lid, so that the sticky sides of the tape are covered. I chose to tape around the hat Horizontally, but whatever suits your needs will work at this point.
Step 7: There Is No Step 7...
You're done. Try it out and see if it fits. If you want, you may want to add some stickers or something to it or personalize it, but other than that, that's it.
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