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, 09 2013 . 01:41 +
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How to make a Barbie size (or bigger) doll's straw hat

Sorry about the photos, I did most of this at night.

The only thing you need to buy to make this is a bundle of hat straw. In the US you can order from The PNB Doll Company ($9 for a 10 yard bundle, 1/4" wide), in Europe from Gildebrief (19,90€ for a 10 meter bundle, 4,5 mm wide). The rest of the materials can be found in your home.

The particularity of this straw braid is that on each side, there is a string which you can pull in order to make the braid fit any curve. Here's a photo to illustrate what I mean.

Braid

Find a box or other cylindrical object with the desired diameter for your finished hat. Cut a circle in card stock of the same size, put it on top of the box, cover with plastic wrap and hold the film in place with an elastic. Glue a PET bottle cap of the same size as your doll's head in the center of the plastic wrap.

You can adapt this method to bigger dolls by using various kinds of plastic caps.

Chap1

Cut a strip of double-sided tape, about 1/4 to 1/3" wide, and press it all around the outer edge of the film-covered card stock, so that it lays flat in a circle on the top of the box.

With a needle, pick up the string on the side of the straw braid which will be facing inside, and pull on it in order to make the braid fit the curve. Then press the first row of straw on top of the tape.

Chap2

Next, pour white tacky glue into the corner of a small Ziploc bag, tie the corner tightly with a piece of string or wire, and cut a very tiny hole at the tip of the corner, so that you can press out a very small bead of glue while holding the corner of the bag with your fingers. Deposit a small amount of glue all around the inner edge of the first row.

Chap3

Press the second row of braid over the first one, in a concentric circle, so that it overlaps about half the width of the braid. Continue in this way until you've reached the top of the cap. Don't forget to pull on the inner string when needed in order to make the braid fit the curves. As the circles become smaller and smaller you will need to pull more often on the string.

Each time you've securely glued in place a section of braid with the string pulled out, you can cut the string close to the edge of the braid just before glueing the next row over it.

Chap4

When you reach the junction with the bottle cap, press the edge with your fingernails to make the braid follow the shape of your hat "mold".

Chap5

To finish, when you only have a small hole left open at the very top, simply cut the braid, fold it over itself and glue it in the center.

Let dry overnight and remove from the mold. If you wish to decorate the brim, pick up one of the thick strands of straw in the braid, and pull on it. The braid will "gather" itself and look like ricrac.

Chap6

Glue the straw ricrac all around the brim edge. Here's the finished hat seen from above.

Chap7

And here's the hat seen from inside.

Chap8

if you wish to shape the hat, place it on top of the PET bottle whose cap you used, with the cap on the bottle, secure it in the desired shape by taping a piece of string to the sides of the bottle, and steam the hat by holding it above a pot of boiling water for a few minutes. Let dry.

Chap9

Trim the hat according to your tastes. I wanted to keep this one relatively simple so for the inside I just glued ribbon trim all around the inner edge of the brim.

Chandrahat3

I glued ribbon around the crown and hid the junction with a small ribbon bow. At first I added a bunch of flowers on the side, but decided they didn't look good. It seems to me flowers look good on the side of a hat with a rounded top but not when the top is flat. Well, live and learn. I ripped the flowers off and in order to hide the glue stain where they had been glued a bigger ribbon bow. If you like you can also add ribbon ties glued either to the inside or the outside of the hat, tying either in front or in back.

Chandrahat2

Voilà! I hope someone will find this useful and if you try it, I'd love to see photos.

Chandrahat

Update : here are photos of a hat the talented Diane made using this tutorial, and bigger objects to make her mold. Diane's doll has a head circumference of about 6-7 inches.

Diane1

Diane2

(photos posted with Diane's permission)

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