How to Make a Cowboy Hat Out of Paper or Cardboard
To make a cowboy hat out of paper, cut a big oval brim from cardboard or poster board with a head-sized hole in the middle, roll a strip of paper into a tall crown that fits your head, pinch the top of the crown into a dent, glue the crown into the brim, then curl the brim sides up. Paint it brown, black or pink, add a band, and you've got a DIY cowboy hat in about an hour.
If you've got the hat sorted but not the rest of the cowboy (or cowgirl) look, The Costume Rack builds the whole costume piece by piece from your closet: Start my costume.
Most paper cowboy hat tutorials online are made for kindergarten crafts, which is why they end up sitting on top of your head like a party hat. This guide is sized for a teen or adult head, and it's built to survive a football game, a Western day, or a country vs country club party.
Materials for a cardboard cowboy hat
| You need | Best option | Also works |
|---|---|---|
| Brim | Thin cardboard (cereal box or pizza box lid) | Poster board, two layers of cardstock |
| Crown | Poster board or cardstock | A brown paper grocery bag |
| Glue | Hot glue (low temp) | Craft glue plus tape |
| Paint | Brown, black, tan or pink acrylic | Brown paper bag = already brown |
| Band | Rope, ribbon, a bandana, or a belt | Painted stripe |
| Tools | Scissors, pencil, string, tape measure | A phone charger cable as a measure |
Paper bag hack: a cowboy hat out of a paper bag looks surprisingly real because the crinkly brown texture reads like suede. Scrunch the bag up, flatten it out, and use it for the crown.
Cut the brim
The brim is what makes it a cowboy hat and not a top hat, so size matters.
Step by step
- Measure your head. Wrap string around your forehead where a hat would sit, just above your ears. Write that number down. For most teens and adults it's somewhere around 21 to 24 inches.
- Draw the head hole. On the cardboard, draw an oval (not a circle, heads are longer front to back) that matches your measurement. An easy way: trace a hat you already own, or a bowl, then stretch it into an oval.
- Draw the brim edge. Draw a bigger oval around the head hole, about 3 to 4 inches out on every side. Make the front and back slightly longer than the sides.
- Cut the outer edge first, then poke a hole in the center and cut out the head hole.
- Cut tabs. Instead of cutting the head hole exactly, cut it half an inch smaller, then snip small slits all the way around to your real line. Fold those little tabs up. You'll glue the crown to them.
Cowboy hat template shortcut
No template? Trace a dinner plate for the outer edge on smaller heads or use a large pizza box lid for adults. It's the right scale almost every time.
Build the crown
The crown is the tall part your head goes in.
- Cut a strip of poster board about 5 to 6 inches tall and 2 inches longer than your head measurement.
- Wrap it into a ring that fits your head with a little room, overlap the ends and glue or tape them.
- Slide the ring down onto the tabs of your brim, tabs on the inside of the ring, and glue each tab to the inside.
- For the top: trace the top of the ring onto cardstock, cut it out a little bigger, snip tabs around the edge, fold them down and glue them inside the ring.
Get the classic cowboy dent
Here's what separates a paper cowboy hat for adults from a toddler craft:
- Pinch the top of the crown front to back, so it folds into a long dip down the middle.
- Push in the two sides at the front with your thumbs to make a little "pinch."
- Tape inside to hold the shape.
That dent is the difference between "cowboy" and "birthday hat." Don't skip it.
Shape and paint your DIY cowboy hat
How to curl a cowboy hat brim
- Lightly wet the sides of the brim with a damp paper towel (don't soak cardboard).
- Roll each side up around a thick marker or a rolling pin.
- Hold it with clothespins or binder clips while it dries.
- Leave the front and back flatter so it dips down in front, like the real thing.
On thicker cardboard, score a line along each side of the brim with a butter knife first so it folds instead of cracking.
Painting
- Brown or tan: the classic. Dry-brush a darker brown over the top for a worn, leathery vibe.
- Black: outlaw energy. Pairs with a black bandana.
- Pink, white or glitter: the cowgirl hat DIY that goes hard at a bach party, a concert or Western spirit week.
Let paint dry fully before you add the band.
The band
Glue rope, ribbon or a folded bandana around the base of the crown. A strip of old belt with the buckle at the side is chef's kiss. Want extra? Add a small feather, a sheriff star cut from foil, or a strip of rhinestone stickers.
Hat done, but the rest of your cowboy costume is still a vague "I think I have boots?" The Costume Rack splits the cowboy into pieces, shows where to find each one or a version made from things you own, and gives you three put-together steps so it looks like a costume, not an outfit. Start my costume
Make it fit a teen or adult head
A hat that falls off is worse than no hat. Fixes:
- Too loose: glue a strip of folded paper towel or foam inside the crown band at the forehead. It works like the sweatband in a real hat.
- Too tight: cut a small slit at the back of the crown ring and cover it with the band.
- Keeps blowing off: tape an elastic or ribbon chin strap to the inside of the crown. Cowboys literally used these, so it's historically correct.
- Hair in a high pony or buns: cut a small hole in the back of the crown for the pony to poke through.
Finish the cowboy costume at home
A cardboard cowboy hat plus closet basics is already a full costume:
- Flannel or denim shirt
- Jeans
- Boots (any boots, honestly)
- A bandana around your neck
- Optional: a belt with a big buckle
Doing a group? Cowboys pair with a sheriff, a horse, or a whole saloon. Trying to plan a squad costume for your guys? Check our Halloween costumes for 3 guys or the 2-guys duo ideas.
Your cowboy look, done in the next two minutes
You now know how to make a cowboy hat out of paper. The Costume Rack handles the rest: tell it your vibe and what's in your closet, and it matches you to a costume, cowboy included, with every piece listed and a no-makeup version. Share one link so your friends claim their own costumes on your rail, so you don't end up with four cowboys and zero horses.
FAQ
How do you make a cowboy hat out of cardboard for an adult?
Measure your head with string, cut an oval head hole to that size in a large piece of cardboard, and draw a brim 3 to 4 inches out. Build the crown from a strip of poster board 5 to 6 inches tall, glue it to tabs around the head hole, and pinch the top into a dent.
Can you make a cowboy hat out of a paper bag?
Yes, and it looks great. Scrunch and flatten a brown grocery bag for a suede texture, use it to cover the crown and brim, and you won't even need paint.
How do you curl the brim of a paper cowboy hat?
Dampen the sides slightly, roll them around a marker or rolling pin, and hold them with clips while they dry. Scoring the cardboard first stops it from cracking.
What's the easiest cowgirl hat DIY?
Use the same method as the cowboy hat and paint it pink or white, then glue on rhinestone stickers or a feather band. It's a go-to for Western spirit days, concerts and themed parties.
How long does it take to make a DIY cowboy hat?
About an hour of building and cutting, plus drying time if you paint or wet the brim. Do it the day before so the paint and the curl set properly.