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DIY Witch Costume Hat

By: Emily Schmidt

At a Glance:

Project #15347 Skill Level: Intermediate Time:
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This project features these great brands:

  • Glitterific Logo
  • Mod Podge Finishes and Formulas Logo
supplies

Apple Barrel ® Gloss™ - Pumpkin Orange, 2 oz.

Number Needed: 1 $1.29
Item not for sale on Plaid Online.

Apple Barrel ® Gloss™ - Golden Yellow, 2 oz.

Number Needed: 1 $1.29
Item not for sale on Plaid Online.

Apple Barrel ® Gloss™ - White, 8 oz.

Number Needed: 1 $4.99
Item not for sale on Plaid Online.

FolkArt ® Glitterific™ Acrylic Paint - Princess, 2 oz.

Number Needed: 1 $4.99
Item not for sale on Plaid Online.

FolkArt ® Glitterific™ Acrylic Paint - Gold, 2 oz.

Number Needed: 1 $4.99
Item not for sale on Plaid Online.

Leather Studio™ Leather & Vinyl Paint Colors - Amethyst, 2 oz.

Number Needed: 1 $2.99
Item not for sale on Plaid Online.

Leather Studio™ Leather & Vinyl Paint Colors - Black, 2 oz.

Number Needed: 1 $2.99
Item not for sale on Plaid Online.

FolkArt ® Color Shift™ Acrylic Paint - Purple Flash, 2 oz.

Number Needed: 1 $4.99
Item not for sale on Plaid Online.

Folkart ® Brush Sets - Artist Variety Set, 10 pc.

Number Needed: 1 $7.99
Item not for sale on Plaid Online.

Mod Podge ® Gloss, 8 oz.

Number Needed: 1 $6.99
Item not for sale on Plaid Online.
instructions

Other Supplies

  • Witch Hat Pattern by Kinpatsu Cosplay 
  • 5-6 mm eva foam                                     
  • Contact cement                                      
  • Hot Glue                                            
  • Super glue                                          
  • Scissors                                            
  • Craft knife                                         
  • Cutting mat                                         
  • Heat gun (can use a blow dryer on the hot setting)  
  • Used plastic grocery bags                           
  • Ribbon                                              
  • Scotch tape                                         
  • Silver marker or sharpie                            

Instructions

Note: We downsized the size of the hat and printed it at 85%. Instructions on how to do this can be found in the pattern documents. 

  1. Tape together your pattern, transfer onto EVA Foam and cut out. Try to make your cuts as close to a 90 degree as possible. To help the tip of your witch hat come together, cut your patterns at an angle on either side of the 90 degree angles. This tapers down into the point. It will help you when attaching all the pieces together.  
  2. To heat seal and shape your EVA Foam use a heat gun or blow dryer, using the hottest setting. Remember to continuously move the tool over the surface of the EVA Foam. This helps distribute the heat evenly. 
  3. To round out your pieces roll them while heated. You can exaggerate this curve because once the foam cools it will release a little. Having the foam shaped helps reduce resistance when connecting all the pieces together. 
  4. To connect your pieces together, use two thin layers of contact cement around the edges. The first layer seeps into the foam because it is porous. The second layer is what creates the adhesive properties. It should feel like the sticky part of a posted note. Work slowly, applying pressure as you go to try and reduce seam lines by having all of your sections line up.  
  5. You'll notice that if you squeeze the top of the hat it is squishy; to help with this, stuff with used plastic grocery bags. To keep the bags from coming loose, hot glue a piece of foam into the inside. Trace out the opening to the brim from your pattern onto a piece of foam and cut it smaller. This will allow the foam to block of the bags and allow your head to still fit into the hat. Once satisfied, glue with hot glue on the inside and allow it to cool.
  6. Once the top section has been glued together, use the same technique to glue on the rim of the hat. 
  7. To add a belt detail onto your hat. Use super glue to attach the belt to the hat base. 
  8. Use 2-3 layers of Mod Podge Matte all over the surface of your foam witch hat. Allow each layer to dry completely before adding the next. 
  9. Base coat with Apple Barrel Gloss Black. For the top portion of the witch hat, use two layers of FolkArt Dragonfly GlazeGold-Red-Violet Shift using a Flat 3/4" paint brush. 
  10. Paint a large spider web along the seams of the hat. 
  11. The bottom of the witch hat is base coated using Apple Barrel Gloss Deep Purple and topped with FolkArt Glitterific Princess.
  12. The belt portion follows the same painting technique as described in the shoe section of these instructions. 
  13. To seal your painted hat, use Mod Podge Ultra in Gloss.  
  14. To help your witch hat stay in place, place on head and add a ribbon. Cut enough ribbon to attach to the inside of the hat and still be able to tie a bow under your chin with slack. Score the inside of the hat where you want to attach the ribbon using a craft knife. This allows the hot glue to have something to adhere to. Hot glue ribbon to underside of hat.      

Disclaimer: The information found in each project is presented in good faith, but no warranty is given, nor results guaranteed, nor is freedom from any patent to be inferred. Since we have no control over physical conditions surrounding the application of information herein contained, Plaid Enterprises, Inc. disclaims any liability for untoward results.

Important: Please be sure to thoroughly read the instructions for all products, paying particular attention to all cautions and warnings shown to ensure the proper and safe use of the product.

Copyright: All Rights Reserved. No part of this Project may be reproduced in any form without permission in writing, except for your personal use, except by reviewer, who may in reviewing this project, quote brief passages in a magazine or newspaper.

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