If it's been a while since you've read Dr. Seuss's classic "Green Eggs and Ham," Sam-I-Am is the one who already loves pork and eggs verde and wears a red rounded top hat. His culinary conservative companion is the one who does not want to eat green eggs and ham under any circumstances; his hat is taller and black. You can make your own Sam-I-Am hat for any costume occasion from a Halloween party to a Dr. Seuss-themed birthday bash.
Make a pattern. Measure around your head to determine how big around your hat and brim must be. Draw a circle that is that measurement in circumference on a sheet of yesterday's newspaper. Draw another circle that circle with four inches of space between the two circles. This the pattern for the brim of your Sam-I-Am hat. For the body of the hat, draw a filled-in "U" shape that is 1/2 the width of your head measurement plus one inch. The filled-in "U" should be 12 to 16 inches high; the bigger the head, the taller the hat. Cut out the patterns.
Choose and cut out the fabric. Select a thick sturdy fabric that can hold its shape well. Felt is good, so is broadcloth. Pin the patterns to the fabric and cut out, cutting an extra 1/2 inch on all outer sides for seam allowance. You will need two of the filled-in "U" pieces and one brim piece.
Sew the hat. Stitch the two "U" pieces together, right sides together to create a tube with a rounded end. Stuff the top half of the rounded end tube with polyester fiberfill. Over-stuff the very top so it will fall forward slightly like Sam-I-Am's hat does in the story illustrations. Cut a piece from your leftover fabric in an oval that will act as a barrier to hold the fiberfill in place. Hand-stitch the oval into place.
Add the brim and finish. Stitch the brim piece onto the hat bottom, right sides together. If your fabric is felt, you are finished. If the fabric is not felt, fold under the outer edge of the hat brim 1/4 inch. Repeat and stitch as close to the first fold as possible to hem. Your Sam-I-Am hat is complete and ready to wear. Pair with a bright yellow turtleneck sweater, dye some fried eggs and a ham green, and you are ready to go.