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Cia's Hat Tutorial- Hyrule Warriors

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Materials:
  • craft foam
  • masking tape
  • measuring tools
  • plastic wrap
  • paper for pattern
  • foam board
  • expanding foam
  • Worbla or other thermoplastic
  • craft knife
  • scissors
  • hot glue
  • fabric
  • double sided tape
  • resin and molds to cast gems
  • nail polish to paint gems
  • magnets
  • spray primer
  • paints/paint brushes


1. I made a base for my hat to fit on my head. I made it out of craft foam and held it together with masking tape.


2. I made a pattern for the points by drawing it out on paper and measuring a lot.  

3. I cut out the points from foam board and hot glued them to my craft foam hat base.  

4. I covered the points in expanding foam and let it cure. Don't ask my why the foam is two different colors. I don't know. It came out of the can that way DX

5. I carved the shapes out of the expanding foam and added a strip of Worbla around the bottom edge to give it a bit more durability.

6. I made a fabric cover for the hat. I wrapped the entire hat up in plastic wrap and masking tape and drew seams wherever I needed seams, cut it out, and used it as a pattern for the fabric. Once it was sewn together, I just slipped it over the hat.

7. Once I had put the cover on, I wrapped the fabric over into the inside of the hat. I stuck it down with double sided adhesive tape first, and then hot glued it in place for a more secure hold.  

8. Hat is all smooth and purple and nice.

9. I made paper patterns for all the "metal" looking pieces and cast some gems out of resin.  I also painted their backs with nail polish to give them color.

10. I used the paper patterns to cut out foam pieces.  

11. The swirly details that go on the sides of the hat didn't need a foam base, so I just cut those out of double layer thick Worbla.  

12. I attached pieces together where necessary. I have the gems in for the picture, but I don't glue them in until the last step.

13. I covered all the foam pieces with Worbla and formed them around the hat.

14. Up close detail of the back of the hat. I have everything attached together with magnets so I can easily take it off and put it back on.  

15. Last, I primed and painted everything and glued in the gems.  

I also keep the hat attached to my head with magnets. I have one glued on the inside of the hat and another sewn into my wig.

Any questions, feel free to ask! :D (Big Grin) 
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