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step 1 - cutting out parts
so you print out the patterns and pin them to the fabric as shown.
then cut out the fabric and pattern along the lines (not the dotted lines, those are where you'll be sewing).
you see in this pic how i use the two-part patterns for larger pieces.

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  • note again: for each part you'll need to cut more than one piece of fabric.
    top: 1 part wool and 1 part cotton
    sides: 2 parts wool and 2 parts cotton (don't cut all these at once, it'll probably be too thick to cut properly)
    flaps: 2 parts wool
    bill: 2 parts wool

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  • note: when cutting out the bill of the hat, you pin the pattern to the wool and cut around the outer line. then you unpin the pattern from the wool and you'll use the pattern again.
    take the pattern of the bill left over from fabric cutting, and glue it to your soft cardboard.
    make sure the corrugation is aligned so that the bill bends easily down on the sides.
    then take a utility knife or something and cut the cardboard out on the inner pattern line.

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