Beer box hats are popular accessories for frat parties and tailgating, and luckily they’re cheap and relatively easy to make. Here’s how to make a beer box hat for yourself:
Start with three empty beer boxes (the kind that holds 24 cans of beer.) Make sure they are whole and don’t have any tears or damage. Depending on the look you want, you can stick to one brand of beer or choose different brands for your hat. Unfold each box carefully and place the printed side down (brown side up) as you flatten each box.
Using a piece of string, measure the size of your head by wrapping the string around the largest part. Mark or cut the string on the spot where it intersects itself.
To create the body of the hat, you’ll need your piece of string again. Lay the string flat along the edge of the third box. Mark on the box where the string ends. Add another inch or so, so that you can overlap and secure the body of your hat. Next, measure a straight line parallel to the edge you just marked. The distance between the two lines will be the height of your hat (at least four inches is recommended, but you can make it larger if you want a taller, top-hat style.)
Cut along the lines so that you have a long strip of cardboard. Fold half an inch along one long edge of the strip, inside (towards the brown side.) Then fold half an inch along the other long edge, this time to the outside (towards the printed side.) Bring the two ends of the strip together and secure with glue or packing tape.
Place the top (circle) hat piece on the tabletop with the brown side facing up. Place the body of the hat on top of the circular piece and make sure all the edges line up together. Use clear packing tape on the brown cardboard side to stick the two pieces together. Flip the joined pieces right-side up.
Slide the brim all the way down the joined pieces so that it sits on the bottom edge that is folded out. Use clear packing tape to attach the brim to the rest of the hat all the way around. That’s it – your amazing beer box hat is complete! Make sure it fits correctly and you’re done.
Some more resources:
Hat Seller: http://www.redneckbeerhats.com/
Another How to : http://www.wikihow.com/Make-a-Beer-Box-Top-Hat
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