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Submitted on
October 31, 2012
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Chapeau by Xero-Cosplay Chapeau by Xero-Cosplay
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This is version 1.5 because I made a few mistakes being this was my first trip into hat-town. Pretty happy with it, I must say.

Materials: wonderflex, resin, suede, model magic, acrylic paint.

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ChurlishPrurient Featured By Owner Jun 20, 2014  Hobbyist General Artist
I have a question.. How would I go about making a hat like this?
I want to be sally whitemane for a con next year and I've already started on her costume.

I just have no idea how to go about making a hat like this :( the general shape seems kinda hard.

Are there any tips you  could give me? I'd be more than grateful :icontearplz:
Xero-Cosplay Featured By Owner Jul 30, 2014  Hobbyist General Artist
The hat was by far the most difficult and most time consuming part of this costume, no argument. I started the project by using "WoW Model Viewer" (a program downloaded online) to get the best views of Whitemane's hat. I created a pattern out of paper that was modified over and over until the shape was right. There were 4 main pieces to the hat when finished:

1. The band around circumference of the head.
2. The angled sides of the hat (which is just a crescent shape, a few inches wide)
3. The top of the hat
4. The front inside peak of the hat that connects the top to the sides.

The final copy is made out of thermoplastic but paper can act a lot like thin plastic when cooled. Once I had all of these basic shapes made out of paper, I laid them on the plastic and cut them out. I heated the edges and fitted them all together, reinforcing with extra layers of thermoplastic when needed. (Sorry I don't have photos of this part of the process right now)

I initially used vinyl for the black parts of the hat but it didn't stick so I just painted it black instead. The red areas are the same red suede that I used on the rest of the outfit, just cut to shape using the original paper pattern and glued in place. All of the gold areas are made using Model Magic and and a clay extruder to keep the lines consistent in thickness. The Model Magic was allowed to dry, painted, and glued to the hat. The filigree details in the front was also made using Model Magic but it was shaped freehand with sculpting tools. The gem in front is actually a half-dome acrylic shape that I got from and painted the back with nail polish. Here is another picture of the hat in progress:

ChurlishPrurient Featured By Owner Aug 2, 2014  Hobbyist General Artist
Wow that was a very nicely detailed reply! Thank you so much!
Honey-Hime Featured By Owner Mar 8, 2014  Hobbyist General Artist
You're so talented wow! I hope I can make cool stuff out of model magic when I get some uwu
Xero-Cosplay Featured By Owner Mar 10, 2014  Hobbyist General Artist
It can be tough to work with but it's one of my favorite materials. :) Give it a shot!
lookitsnichole Featured By Owner Sep 9, 2013
Thank you for saying what you used to make this! I've been thinking I want to make a Whitemane cosplay, but I had no idea what to do to make a hat.
Xero-Cosplay Featured By Owner Sep 10, 2013  Hobbyist General Artist
Glad to here it was inspirational. :)
Damien-the-Ogre Featured By Owner Jan 2, 2013  Hobbyist General Artist
It looks absolutely fantastic! I'm very much looking forward to seeing the finished costume. :D
Xero-Cosplay Featured By Owner Jan 4, 2013  Hobbyist General Artist
Thank ya! I'll have it finished by the end of the month so check back. :D
Damien-the-Ogre Featured By Owner Jan 6, 2013  Hobbyist General Artist
Will do!
Presumably wonderflex is similar to worbla? Or is there any difference between the two?
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