Today I started working on the brim of my top hat. The brim has the most work of all the parts, and sets the fit and style of the hat. Everything is built from the head out and the first thing you need to know is what size hat are you making? The brim has a wire on the inside that keeps it a specific size. My head measures 22 3/8". The formula I use to determine what size to set the headsize wire at is headsize + 5/8". This allows for the thickness of the felt and fabric and a leather sweatband. I then consider the shape and style I want for the brim. Since the object of this hat is to have Neopixels around the brim for navigational purposes, I want a slightly larger and more theatrical proportion. I chose to have the brim be 2" in front, 2 18" in back, and 2 3/4" at the side with a lip of 1/4" front and back, 1/2" at each side. I cut cardboard rectangles of each measurement to help draw the shape out. Hat making supplies can be found at Hats by Leko, Wholesale Millinery Supplies, importer/exporter. They also offer a less toxic felt stiffener.
I put together a video outlining each step needed to make a brim shape from flat felt and wire. There is no sound.
Coming up Next...
Making the sideband.