I like disco balls, thought it would make a cool Hat. Ok what you need, a cheap Visor ( no matter what color ), then Cutable Flexible mirror, Sharp sisors, Hot glue gun ( low/multitemp ) with plenty glue stix. Fine sharpy perment marker, and about an hour to spare. I got all the stuff from my local Walmart.
Step 1: Gather Supplies
Ok First i got a cheap visor, any hat place. Then I went to Walmart, in the auto section I got a Cutable Flexible Mirror ( it's lighter than real mirror, and a lot safer ), then a Hot Glue Gun and Lots of Glue stix ( Use low/Muti temp so it don't melt Mirror ) then get sharp Sissors, Sharpy Marker, Ruler, and about an hour to put together.
I took the Mirror out the package, on the back I took my ruler and Marker and made a grid, One Visor I made a grid of 1/2 inch squares, and another i made 3/4 inch squares. The larger are easier to cut, and glue, but don't flex as much. The smaller squares are harder to cut, and glue, but keep the visor more flexible.
Step 2: Mark Your Lines on Visor for Starting Point
I wanted the Mirror lines to be as straight and even as I could get them even with the curve of the Visor. So I used a pencil or marker and made some marks to have my start point.
Step 3: Start Your Glueing
I took the first square and started at the bottom ring, I figured that's what people see when they first see me. So after the Hot Glue gun got nice and hot, I put a large dollop on the hat and positioned the first square. Then I did the second, making sure to stay even as I could, it's kinda like laying down tile on your floor.
When i would get to an edge that the whole square wouldn't fit I placed it where i wanted it to go and used the Sharpie behind the square to mark where to cut. Then I put hot glue, and placed the newly cut square. It keeps the edge looking straight and clean. I kept the same steps for the bill, but i had to make more individual cuts since it curves more.
Step 4: Keep It Clean As You Go
As you keep Glueing you will get strings or hairs of Glue that Crosses the Mirror Squares. If you Clean them as you go it won't b so bad and look allot cleaner and neater. The cleaner you keep it, in the end the mirror will look better, shinier, and People can't tell what you used to hold the squares in place. When done I put a bead of glue around all the edges. I did this because people kept asking me to see the hat, and i didn't want them to prick there fingers on any edges, Nor did i want to cut myself on my face, just in case.
When done the hat is still flexible and wearable, it's light and you don't notice anything different then a normal visor. But everyone around you will notice, and the brighter the room the more the effect, and since your moving unlike a regular Disco Ball, the lights go everywhere.