I made this hat for a friend. It was my first attempt and hit a few bumps along the way, but got there in the end. Just be sure to take into account the thickness of your material when taking head measurements and add this to you measurements for the crown.
Hope my instructions are clear enough!
Measure the circumference of your head (60cm). Cut a length of poster board using this measurement and 16cm in height. Join the ends and stick with tape. This is the crown of your hat.
For the tip of your hat cut out a circle of cardboard slightly larger than the circumference of the crown (depending on how much of a curve you want on the top of your hat). I used a plate that was approx. 2 cm wider in radius than the crown.
Tape the tip to the crown and then secure with hot glue.
Glue the fabric around the edge of the tip of the hat. Stretch the fabric down to the base of the hat and glue to the inside of the crown.
Cut out a circle of material the same size as the tip of the hat and use hot-glue to secure.
Next I made the brim. Trace the circumference of the crown on the material you will use for this section. Cut a hole in the middle of this and slice to the edge of the circle, creating several tabs. Glue these tabs to the interior of the crown.
Next cut a loop of wire approx. 8cm wider than the circumference of the crown. Join the ends with tape.
Pull the fabric tightly over the wire and pin.
Then I hand-sewed the fabric just inside the wire frame and trimmed off the excess.
Finally I spray-painted it black as I had just used spare fabric I had at home.