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How to Make a Giant Foam Cowboy Hat

Updated April 17, 2017

We have all seen those big floppy cowboy hats at fairs or as part of a costume. They are an attention-getting accessory that you can buy in costume and novelty shops. Instead of spending the money to buy one, you can get your kids involved in making their own. They can make one in any colour and add their own custom touches. All you need are some easy to find craft supplies and little bit of time.

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  1. Measure the head of the person who is to wear the hat.

  2. Measure a piece of foam that is a half-inch longer than the circumference of the person's head. This gives you a little extra length for gluing the ends together. Make the width of this piece as tall as you would like. If you want a 10-gallon hat, make it eight or 10 inches high.

  3. Choose a shape for the top of the hat. If you want the hat to be flat on top, just leave it as is. If you want it rounded, just fold the piece in half and round the top edge.

  4. Roll the foam piece into a teardrop shape and glue the ends in a half-inch seam.

  5. Make the lid of the hat once the glue on the top dries. Lay the top on the foam and trace around it to create the lid piece. Cut out the lid and glue it into the top of your hat. Set aside to dry.

  6. Measure the brim of the hat. Again, make this as big as you want. The roll of foam is normally around 3 foot wide and five feet long. You might want to cut a 3-by-3 square or larger. Once you cut the piece, use scissors to round out the edges.

  7. Cut a hole in the middle. Use your finished top piece as a guide to draw an outline for the hole in the brim. Cut out the middle piece.

  8. Attach the top piece to the brim. Glue the top into the hole in the brim. Let dry completely.

  9. Lift the sides. Use glue to hold the sides of the brim in place against the sides of the top piece. This creates the rolled brim of the cowboy hat. Run a piece of string completely around the middle of the hat to hold the sides in position. Allow to dry over night. Remove string when glue dries.

  10. Decorate the hat. Use markers and stickers to create a one-of-a-kind design.

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Things You'll Need

  • One roll craft foam
  • Craft Foam Glue
  • Tape measure
  • Scissors
  • String
  • Markers
  • Stickers

About the Author

Heather Mckinney

Heather Mckinney has been writing for over 23 years. She has a published piece in the University Archives detailing the history of an independently owned student newspaper. Mckinney holds a Bachelor of Arts in history from University of Texas at San Antonio.

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