Cut a large circle (about 18 inches wide) from cardboard for the brim. Then cut a smaller circle in the middle for the hat opening.
Roll a separate cardboard piece into a tall cone, around 20 inches high, and glue or tape it into shape.
Glue crumpled paper around the cone to shape the hat’s face such as eyebrows, mouth, and wrinkles. Secure tightly.
Glue the cone to the brim’s center, reinforcing it with tape or hot glue underneath.
Cover the hat with brown paper, crinkling it slightly for a worn effect. Smooth and glue down the edges.
Once dry, paint the entire hat in dark brown, then dry-brush lighter brown for highlights and aging.
