How to make a Mini Cowgirl / Cowboy Hat DIY

Book week is fast approaching and parents everywhere are hunting the shops for those crucial costume details that complete the book characters look. I have noticed that there are no Cowgirl hats in any local stores at the moment, working in a party shop like I do makes you notice these things LOL

So I have created a simple western hat pattern you can alter to create different characters for boys and girls, a Jessie & Sheriff Callie tutorial is included. ENJOY this DIY!

MINI COWGIRL HAT TUTORIAL DETAILS

Basic Craft skills

Approx cost $6

Approx time 10 mins

SUPPLIES TO MAKE A COWGIRL or COWBOY Hat

Glitter foam
Headband or Hair comb
Craft glue
Scissors
Fishing Line or cotton
Free pattern template

JESSIE's Hat from Toy Story

+ White Thread

SHERIFF CALLIE's Wild West Hat
+ Pink Ribbon
+ Gold Cardboard

STEP 1

Print the free A4 cowgirl hat template and cut it out. You can find the template at the bottom of this page.
Trace the template on foam and cut it out. Use the foam colour of your choice to match the character you are creating. This template also works with thick cardboard instead of foam.

STEP 2

Curl the top part of the hat template into a cone, and match up the base edges. The cone should be in a cone shape going in at the top.
Check to see if the cone fits into the hat base.
Glue the edge of the cone together and let dry. Clamp with pegs

STEP 3

Push the cone 3/4 through the base.
Glue around the whole edge of the base
Push the rest of the cone through to the bottom, where the glue is and let it dry

Your basic Cowboy/Cowgirl Hat is now finished, decorate how you please with ribbons, cardboard etc. Glue the hat to a hair comb or headband. This is where you can be creative with your handmade crafts and have some fun.

TUTORIAL | MAKE YOUR OWN SHERIFF CALLIE Wild West Hat
Make your base as above with pink foam

Step 1
Glue pink ribbon around the hat, overlapping at the back.

Step 2
With gold cardboard draw a star to fit the front of the hat, cut it out and glue it to the front.

Step 3
To curl up the edge of the hat, thread the fishing line or cotton through the edge and centre of the hat and tie it off tight, which is a simple way to keep the edge up and create the cowgirl hat shape.

Every little girl will love this Sheriff Callie DIY Hat, especially if they are obsessed with the Disney Cartoon as much as my niece is.

TUTORIAL | MAKE YOUR OWN JESSIE Cowgirl hat from TOY STORY
Step 1
Make your base as above with red foam

Step 2

With some white or cream embroidery thread, start stitching around the edge of the hat. I spaced my thread approx 1 cm apart. Do not do a blanket stitch, just up and over, up and over. Tie off once you get to the starting point.

Step 3 Put glue over the base of the hat and slowly glue your thread by going around and around, creating a solid colour

Cutest mini Jessie Hat right?

Don't forget this free cowgirl hat template can be used for all different character costumes like Woody & Jessie from Toy Story, Yosemite Sam, Sheriff Callie, The Lone Ranger, Jessie James, Brisco County Jr or even your favourite Country singer like Dolly Parton. Easy DIY craft project for Halloween, dress-up parties and creative play.

But don't forget all those book characters from book week you can custom make this hat for!

Happy Crafting & Happy Book Week