I’m making a Jagermonster (from the Girl Genius webcomic) costume that can also function as a Steampunk / Victorian costume of an unspecified hussar (it’s a type of light cavalry with really cool costumes). Of course, that means I need a nice hat.
To make life easier, I bought a vintage band hat (shako) off ebay. So this post is how that hat is constructed in case somebody else wants to do the same thing. I’m sure construction varies depending on company and decade, but this should give you an idea.
The historical shakos were made of stiffened felt and leather. Naturally, modern ones are much cheaper. From the inside out: the base is molded ABS plastic. It’s covered in twill fabric in two pieces – the top and the main part which is sewn in front with the seam hidden by the plaque (the big brass thing). The trim on top is also sewn in front, but the trim on bottom is sewn on one side. The whole fabric cover is glued on the inside and the outside under the trim pieces.. I suspect you could pull the fabric off to use as a pattern, but it would probably have some tears.
Over the twill covering goes the visor with the edge trimmed (printed on the visor is washing instructions: Don’t.) Mine seems to be a layer of stiff card and a layer of vinyl. The visor is sewn onto the inside. Sewn over that is a faux leather (vinyl) sweatband with a headliner attached. The headliner allows some size adjustment. Mine is fabric – I specifically looked for that – but the newer ones are vinyl.
You can see how things go a bit better here, hopefully. The large hole is a vent that I suspect doesn’t help much. The bottom hole I added, so ignore it. The twist ties show the position of the hole for the brad (see below). It looks like a button, but has long metal arms like a brad. Naturally, I can’t get that so I’m using buttons and temporarily holding them with twist ties. The brad holds on the cord and the chinstrap.
The last detail is the plume holder for the plume, pompom, or whatever decoration, which also secures the plaque. This is a flattened plastic tube that goes in a hole in the top of the hat.
The holes are far enough up the hat that you shouldn’t ever feel the screw (which has a small nut that should go on there, but I didn’t bother for the photos). The plaque can turn freely, but I suspect you could solder or glue on another screw to prevent that, since there are three holes.
I think that’s everything. I’ve made a new pompom and I’m going to add fancier cords, like a military shako, that hang from near the top. I’m sculpting a new plaque using the old one as a base. Eventually I’ll make a new, black leather visor, but I think I’m going to run out of time. This is my very rough and ugly mock-up (the plaque will look like brass, not embroidery). I’ll probably also replace the blue trim with gold at some point.
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