DIY Pirate Tricorne Hat: Easy Foam Smithing Tutorial

Updated at: 23/03/2025

Ahoy, mateys! Ever dreamed of sailing the seven seas, a fearsome pirate captain at the helm? While acquiring a real pirate ship might prove…challenging, crafting the iconic symbol of buccaneer bravery – the tricorne hat – is surprisingly simple! This tutorial will guide you through creating your own authentic-looking pirate tricorne hat using readily available foam, proving that even the most landlubber among us can achieve a swashbuckling style. Forget expensive, pre-made costumes; with a few basic tools and some crafting enthusiasm, you'll be sporting a magnificent headpiece fit for any sea-faring adventure.

This project utilizes a straightforward foam smithing technique, perfect for beginners and experienced crafters alike. We’ll focus on easy-to-follow instructions and readily accessible materials, minimizing the time and cost associated with traditional hat making. Ready to transform a piece of foam into a symbol of pirate pride? Let's dive into the step-by-step process and start crafting your very own DIY pirate tricorne hat!

Preparation and Safety Guidelines

Tools Needed
  • 6mm foam sheet
  • 4mm foam sheet
  • Utility blade
  • Heat gun
  • Weldwood contact cement
  • Rotary tool
  • Sanding sponge
  • Bristol board
  • Compass
  • Bob Smith Super Glue
  • 2mm foam sheet
  • Drill
  • Scissors
  • Tin foil
  • Hobby knife
  • Plasti Dip
  • Krylon satin brick paint
  • Liquitex Mars Black paint
  • 1-inch mop brush
  • Damp paper towel
  • Liquitex Burnt Sienna paint
  • Liquitex Raw Sienna paint
  • Valspar gloss
  • Flat clear coat spray
Safety Guidelines
  • Always use sharp craft tools with adult supervision, especially when cutting foam. Point sharp objects away from your body and face.
  • Be mindful of hot glue. It can cause burns. Use caution and avoid touching it until it's completely cooled.
  • When using craft paint, ensure proper ventilation and consider wearing a mask to avoid inhaling fumes.

Step-by-Step Instructions

  1. Cut and Assemble Hat Crown

    • Transfer Part A of the pattern onto 6mm foam and cut out all pieces.
    • Heat and curve each piece before gluing using Weldwood contact cement. Start at the bottom and work your way up, aligning registration points.
    • Clean up seams with a rotary tool and sanding sponge. Apply heat to seal the seams.
    Clean up seams with a rotary tool and sanding sponge. Apply heat to seal the seams.Clean up seams with a rotary tool and sanding sponge. Apply heat to seal the seams.Clean up seams with a rotary tool and sanding sponge. Apply heat to seal the seams.
    Cut and Assemble Hat Crown

  2. Create and Attach Brim

    • Cut a brim from 4mm foam using a compass to make a perfect circle (approximately 17.5 inches). Cut out the inner circle for the hat using the same center point.
    • Cut away the inner circle and create darts around the perimeter. These tabs will attach to the upper section of the hat.
    • Cut a 1-inch by 30-inch strip from 4mm foam. This will wrap around the bottom of the hat, and the brim will attach to it.
    • Mark half an inch up from the bottom of the dome and attach the strip using Bob Smith Super Glue, starting at the back seam.
    Mark half an inch up from the bottom of the dome and attach the strip using Bob Smith Super Glue, starting at the back seam.Mark half an inch up from the bottom of the dome and attach the strip using Bob Smith Super Glue, starting at the back seam.Mark half an inch up from the bottom of the dome and attach the strip using Bob Smith Super Glue, starting at the back seam.Mark half an inch up from the bottom of the dome and attach the strip using Bob Smith Super Glue, starting at the back seam.
    Create and Attach Brim
    • Attach the brim tabs to the strip using super glue.
    Attach the brim tabs to the strip using super glue.
    Create and Attach Brim

  3. Shape and Attach Hat Flaps

    • Glue the two side flaps for the front of the hat, then attach the back flap after the adhesive cures. Apply heat if necessary to bend the foam.
    Glue the two side flaps for the front of the hat, then attach the back flap after the adhesive cures. Apply heat if necessary to bend the foam.Glue the two side flaps for the front of the hat, then attach the back flap after the adhesive cures. Apply heat if necessary to bend the foam.
    Shape and Attach Hat Flaps

  4. Add Leather Straps

    • Cut small strips from 2mm foam for straps. Drill holes through the hat and push the strips through, securing them with super glue.
    Cut small strips from 2mm foam for straps. Drill holes through the hat and push the strips through, securing them with super glue.Cut small strips from 2mm foam for straps. Drill holes through the hat and push the strips through, securing them with super glue.
    Add Leather Straps

  5. Texturize with Tin Foil

    • Apply the tin foil technique to add texture (heat the foam and emboss it with tin foil).
    Apply the tin foil technique to add texture (heat the foam and emboss it with tin foil).Apply the tin foil technique to add texture (heat the foam and emboss it with tin foil).
    Texturize with Tin Foil

  6. Weather the Foam

    • Cut slits and gouges in the foam to add weathering.
    Cut slits and gouges in the foam to add weathering.Cut slits and gouges in the foam to add weathering.
    Weather the Foam

  7. Prepare for Painting

    • Apply several light layers of Plasti Dip to seal the foam for painting.
    Apply several light layers of Plasti Dip to seal the foam for painting.Apply several light layers of Plasti Dip to seal the foam for painting.
    Prepare for Painting

  8. Base Coat and Wash

    • Lightly dust Krylon satin brick paint onto the surface for a reddish tint.
    • Apply a black wash using Liquitex Mars Black paint, water, and a mop brush. Use a damp paper towel to remove some of the paint, creating texture.
    Apply a black wash using Liquitex Mars Black paint, water, and a mop brush. Use a damp paper towel to remove some of the paint, creating texture.Apply a black wash using Liquitex Mars Black paint, water, and a mop brush. Use a damp paper towel to remove some of the paint, creating texture.Apply a black wash using Liquitex Mars Black paint, water, and a mop brush. Use a damp paper towel to remove some of the paint, creating texture.Apply a black wash using Liquitex Mars Black paint, water, and a mop brush. Use a damp paper towel to remove some of the paint, creating texture.
    Base Coat and Wash

  9. Add Wrinkles and Dry Brush

    • After the wash dries, crease the foam to add more wrinkles.
    • Dry brush Burnt Sienna and Raw Sienna paints over the surface, highlighting areas and leaving recesses dark. Remove excess paint with a damp paper towel.
    Dry brush Burnt Sienna and Raw Sienna paints over the surface, highlighting areas and leaving recesses dark. Remove excess paint with a damp paper towel.Dry brush Burnt Sienna and Raw Sienna paints over the surface, highlighting areas and leaving recesses dark. Remove excess paint with a damp paper towel.Dry brush Burnt Sienna and Raw Sienna paints over the surface, highlighting areas and leaving recesses dark. Remove excess paint with a damp paper towel.Dry brush Burnt Sienna and Raw Sienna paints over the surface, highlighting areas and leaving recesses dark. Remove excess paint with a damp paper towel.
    Add Wrinkles and Dry Brush

  10. Seal and Finish

    • Seal with Valspar gloss on selected areas, then spray with a flat clear coat for a waxed, weathered look.
    Seal with Valspar gloss on selected areas, then spray with a flat clear coat for a waxed, weathered look.Seal with Valspar gloss on selected areas, then spray with a flat clear coat for a waxed, weathered look.
    Seal and Finish

Read more: Super Crown Cosplay Tutorial: Fabric Covering for a Professional Finish

Tips

  • Always wear a respirator when heating foam.
  • Use two different balls of tin foil simultaneously for varied texture during the embossing process.

Common Mistakes to Avoid

1. Uneven Foam Cutting

Reason: Improper use of cutting tools or rushing the process can lead to uneven edges and a lopsided hat.
Solution: Use sharp scissors or a craft knife and take your time to ensure accurate cuts along the pattern lines.

2. Incorrect Shaping & Glue Application

Reason: Insufficient shaping before gluing or uneven glue distribution results in a floppy or poorly formed hat.
Solution: Ensure the foam is properly shaped and softened before gluing, and apply a thin, even layer of glue to all joining surfaces.

FAQs

What kind of foam is best for making a tricorne hat?
EVA foam (ethylene-vinyl acetate) is ideal. It's lightweight, easy to cut and shape, and holds its form well. Craft stores usually carry sheets of it in various thicknesses.
Do I need any special tools?
No special tools are absolutely necessary. You'll primarily need a sharp craft knife or utility blade for cutting, a ruler for measuring, and hot glue for assembly. Optional tools include a heat gun for shaping (carefully!) and sandpaper for smoothing edges.