Khepri Designs: Mini Top Hats

I’m making mini top hats. How much fun is that? (In case you want an answer–soooo much!) I am using a tutorial video called DIY Mini Top Hat from the user Threadbanger on YouTube ( that is fantastic–head on over there and watch the entire video before you start your own. It makes it much easier. Trust me!
That being said, one of the reasons I am keeping this blog is so I have an easily accessible place that I store my crafts–a place for me to look back when I want to redo a project and I know exactly what I did the first time around. I have this problem that I try to recreate something I did a long time ago and can’t remember how I did it. (Does that happen to any of you?) And while the video is fantastic, I need my instructions in text that I can quickly scroll through. So here is my text version of what I did, which is essentially Threadbanger’s tutorial:

20130107-173625.jpg1. Cut a 3″ by 12″ piece of card stock. I cut up thick scrapbook paper. Roll this into a cylinder, and tape the end. Scotch tape works fine.

20130107-173755.jpg2. Cut a circular piece of cardboard slightly larger than your cylinder. Threadbanger used an old card box (the kind notecards come in), but I am making a bunch of these, and don’t have enough of that type of board. Cardboard is fine for me–it’s just not as strong on the top, but seems ok.

20130107-173930.jpg3. Hot glue the cylinder to the circle.

20130107-174000.jpg4. Add another round of glue around the join to really attach it.

20130107-174228.jpg5. Start gluing on the fabric–a bit at a time, hot glue the edge of the circle and roll it on the backside of the fabric. Let the circle follow its natural curve–because the top of the hat is bigger, the hat will curve on the fabric. It’s probably not a good idea to use a fabric with a straight line pattern because it won’t stay straight. Finish where you started, with a small amount of overlap. I like to leave the overlap unglued at this point, because it makes it easier to straighten out the fabric when tightening the bottom.

20130107-174557.jpg6. Trim up the fabric. Cut the top close to the edge, and leave a few inches on the bottom (where the hole is) and cut some slits to allow the fabric to be taken to the inside. Trim the fabric so there is a small amount of overlap where it covers the hat (cylinder piece).

20130107-175029.jpg7. Starting from the piece that will be on the bottom of the overlap, pull the fabric taut and hot glue to the inside of the bottom. Work your way around the bottom, pulling taut as you go, until it is all glued. (This is when I glue the top overlap as well.) I then fray check the seam, running a line of it down the overlapping seam. It helps to glue the piece together as well.

20130107-175302.jpg8. Hot glue a piece of fabric to the top, just gluing around the edge. Then trim the fabric.

20130107-175446.jpg9. Using a piece of thick wire (I used 20 gauge, which I think is a little too thin), form a circle. Tape the ends together–masking tape works fine.

20130107-175541.jpg10. Lay the circle of wire on a piece of fabric, and hot glue it together while folding the fabric over the wire. Work in pieces, so this becomes relatively smooth. Trim the excess fabric.

20130107-175726.jpg11. Glue the circle onto another piece of fabric, and trim around the edge.

20130107-180007.jpg12. Now for covering all those cut edges–using a piece of bias tape (I used a folded piece of fabric which seems too big in retrospect. However, I wanted the trim to be a contrasting pattern, and this is what I had.) use tacky glue to adhere the tape around the top edge of the hat, and around the brim circle. I also used fray check on the cut ends of the strip. Smooth this all down.

20130107-180223.jpg13. Apply hot glue around the bottom of the hat piece, and attach it to the brim.

20130107-180405.jpg14. Run a line of tacky glue around the join to be extra secure. Also attach trim around the join with this glue, then let it dry.
15. Add a hair clip to the underside, and you are ready to wear your masterpiece! Threadbanger shows a way to use a ribbon to tie your hat on your head, which I plan on doing with some of my hats. I will let you know how they turn out!
PS sorry about the pictures–I’m usually better, I swear, but I was trying to shoot pictures with my phone while holding a glue gun. It doesn’t work that well!


1 Comment (+add yours?)

  1. psgrannie
    Jan 08, 2013 @ 17:12:42

    How about a pic of the finished hat?


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