How to Make a Western Hat

scissors image by Nedda from

Knowing how to make a homemade western hat can come in handy for a school play, recital or a costume party. The basic shape of a cowboy hat is easy to recreate with some sturdy brown felt and a few other basic tools and materials you may already have on hand, making for a thrifty alternative to purchasing a pre-made hat from a costume shop. The activity can even be a creative project to get little ones involved in.

Some tools can help in making a western hat.
scissors image by Nedda from

Things You'll Need

  • Scissors
  • Measure Tape
  • Pencil
  • Brown Felt
  • Fabric Glue

Measure the diameter of your head to determine the size of the inner brim of the hat. Jot down the measurement and set aside.

Cut out a rectangular piece of brown felt that is the same length as the diameter of your head, and is about four inches wide.

Place the two ends of the strip together to make a loop and secure the ends together with fabric glue. Hold in place until dry.

Lay the felt loop on top of a sheet of brown felt that is about 2 feet by 2 feet. Trace the shape of the oval loop onto the sheet with a pencil.

Cut out the tracing with scissors so there is a hole in the felt sheet.

Draw a line around that hole in pencil that is about six inches broader than the cut out hole, making a brim. Cut along the drawn-on line.

Glue the oval loop to the inside of the felt brim with fabric glue. Hold in place until dry.

Lay the spare piece of felt cut out from the center of the felt square on top of the oval loop that makes the top piece of the hat. Glue in place and hold until dry.


  • Add a paper star to the front of the hat to make a sheriff's hat.


  • Wash hands of any fabric glue to prevent stained clothing.