No toy soldier costume is complete without the signature black hat. You can make your own toy soldier hat out of thin cardboard very cheaply. This is a project kids can make themselves and can be completed in only a few hours. Feel free to get creative with colours and designs to make your hat unique.
Measure the circumference of the child's head by looping the tape measure from the middle of the forehead around the crown of the head and to the other side of the forehead.
Cut a rectangle of thin cardboard that is 9 inches tall and 1 inch longer than the child's head circumference. For example, if the child's head circumference is 20 inches, cut a rectangle that is 9 inches by 21 inches.
Glue the short ends of the rectangle together, slightly overlapping, to create a short cardboard tube.
Set the tube down on a piece of black construction paper and trace around it, making the circle about 1 inch larger than the tube. Cut this circle out.
Measure from the outside edge of one of the child's eyebrows to the other outside edge, and then cut a crescent shape from the thin cardboard that is as long as this measurement and about 2 inches wide at the widest point.
Tape the black construction paper circle to the top of the cardboard tube to make the top of the hat.
Tape the thin cardboard crescent to the front bottom edge of the hat to form the brim.
Use scissors or a hole punch to make holes about 1 1/2 inch from the bottom edge of either side of the hat, just above the ears.
Paint the entire hat black. Allow the paint to dry thoroughly before continuing. Apply clear spray lacquer to make the hat shiny, if desired.
Paint or glue two gold buttons on the front of the hat, about 2 inches above the brim and 2 inches apart. Paint or glue the other two buttons about 1 inch above these buttons. Paint or glue gold cord or braid between both sets of buttons.
Loop some of the gold cord or braid through the holes you created on either side of the hat, leaving enough room to tuck this beneath the child's chin. Trim the edges with gold cord or braid as desired.