Foam Cowboy Hat Tutorial

One of my favorite times of year is Halloween.  I love the costumes, the food and all the fun.  Not so much the scary Halloween but the fun time with family and friends and the excitement leading up to wearing your costume and having fun.  That being said, I also like to make the costumes for my children reusable for the entire year.  Whether they become a staple in their closet or a fun extra to add to the dress up box.

Simple foam cowboy hat tutorial for costumes or dress up

My little ones wanted to be Sheriff Woody and Jessie from Toy Story.  The biggest challenge for this was trying to figure out hats.  My little ones are 3 years old and 9 months.  To find a hat that fit and they'd keep on their heads was going to be a challenge.  That is why I decided to figure out a way to make their hats for them.  Less money, less time trying to search and a great item to add to our dress up box later.

I decided to make their hats out of foam in hopes that they would be a little more comfortable and less expensive.  It was a little tricky, but worked out in the end and they loved them.

Clear Beading Thread (like what is used for jewelry)

Step 1
First, you'll need the measure the head.  Then cut out 3 pieces.  You'll need the rim, the rise and the top.

First, fold the rise in half and stitch it.  Then place the top on the rise and stitch it down.  I used my sewing machine.  It worked out fairly well, not perfect, but that is life.

Step 3
Next, place your rim on your rise and pin it in place.  Since it is foam, pinning is difficult, but this helps it not move as you sew.  Now stitch it down. 

Step 4
Now thread up that plastic jewelry thread and get ready to add the trim around the rim.

I added some ribbon and called it good!

Simple foam cowboy hat tutorial for costumes or dress up


  1. So cool! This is one of the best 31 Days ideas I've seen so far!

  2. Cute!! I need to make these for my kids :)

  3. This is so inventive!! Come over and share if you like. Linda

    I'm following on Facebook, Bloglovin, and Pinterest.

  4. Thank you so much. We need 2 cowgirl outfits in 2 days and you saved the day. Grandma can whip the hats up and the girls will love them thanks.