How to Make a Pirate Hat Out of Paper (Adult Size)

7 min read · The Costume Rack

To make a pirate hat out of paper for an adult, either fold a double sheet of newspaper into a classic bicorn (about 5 minutes) or cut three curved panels from black poster board, staple them to a paper headband sized to your head and fold them up into a tricorn (about 25 minutes). Paint or skull stickers finish it. The poster board version is sturdy enough for a full night out.

If the hat is the easy part and the outfit underneath is the problem, The Costume Rack builds your pirate costume from what is already in your closet: Start my costume.

What you need for a DIY pirate hat

Almost every guide for how to make a pirate hat is written for a 6-year-old's head. The fix for adults is simple: bigger paper, and a measured headband.

You will also want a pencil, scissors, a white or gold paint pen for trim and some skull stickers or white paper to cut a skull and crossbones.

The folded newspaper hat

This is how to make a pirate hat out of newspaper, the fastest route. It gives a two-cornered "bicorn" shape that still reads as pirate.

1. Start big. Use a full double-page spread of newspaper. A single A4 or letter sheet will be too small for an adult; see the note below.
2. Fold in half top to bottom, fold at the top.
3. Fold in half again side to side to make a crease, then unfold.
4. Fold the corners. Fold the top two corners down to meet at the center crease, forming a triangle.
5. Fold the flaps up. Fold the bottom strip on the front up over the triangle. Flip, and fold the back strip up too.
6. Tape the corners where the flaps overlap so it does not spring open.
7. Open and try it on. Gently pull the base open and set it on your head, points to the sides or front to back.

Can you make a pirate hat with A4 paper?

Yes, but it will sit on top of an adult head like a toy. To fix it, tape two A4 sheets together along the short edge first, then fold as above. The same goes for how to make a pirate hat out of construction paper: tape two big sheets together before folding.

Painting newspaper

Newsprint looks fun as it is, but a coat of black acrylic makes it look intentional. Let it dry flat before folding, or paint it after folding and let it dry on a bowl.

The poster board tricorn

This is the captain's hat: three raised sides, a triangle from above. It is the best answer to how to make a pirate hat out of paper easy and adult sized.

Step 1: Make the headband

1. Measure around your head just above your ears. Most adults are between 21 and 24 inches.
2. Cut a strip of poster board 2 inches wide and 2 inches longer than that number.
3. Wrap it around your head, overlap the extra, and staple it into a ring.

Step 2: Cut the three brims

1. On the rest of the poster board, draw a curved panel about 12 inches long and 5 inches tall, like a wide rainbow shape with a flat bottom edge.
2. Cut it out and trace it twice more so you have three identical panels.

Step 3: Attach the brims

1. Space the three panels evenly around the headband so their ends meet.
2. Staple the flat bottom edge of each panel to the headband, from the inside.
3. Fold each panel up so it stands vertical.
4. Where the ends of two panels meet, staple or hot glue them together. These three joins are the three points of the tricorn.

Step 4: Add a crown

For a finished look, cut a circle of poster board to sit on top inside the brims, or crumple black tissue paper into the gap. Many people skip this; from the side you cannot see it.

Sizing it for an adult head

Most failed pirate hats are sizing mistakes. Here is how to get it right.

• Measure, do not guess. Wrap a measuring tape (or a string, then measure the string) above your ears.
• Add 2 inches for the overlap on the headband.
• Hair matters. Wearing a bandana, a wig or big hair under the hat? Measure over it.
• Test before decorating. Put it on, turn your head fast and look down. If it falls, make the band tighter.
• Tilt it. Tricorns look best worn slightly back or tilted, with one point over your forehead.

Measuring your head is easy. Judging whether your white shirt, scarf and boots will look like a pirate captain or just a person in a hat is harder. The Costume Rack does that part: it lists every pirate piece, shows what you can use from your own closet and gives a "Find it" link for the rest. Start my costume

Decorating it

Keep it simple so the shape stays the star.

• Trim. Draw a white or gold line around the upper edge of each brim with a paint pen.
• Skull and crossbones. Cut one from white paper and glue it to the front point.
• Feather. Tuck a real or paper feather into one side for a captain look.
• Weathered look. Dry-brush a little brown or grey paint across the edges.
• Glam. Gold glitter trim for a glam pirate.

Making it sturdy for a night out

Paper hats get crushed, rained on and sat on. A few tweaks help them survive.

1. Double the headband. Glue a second strip inside the first.
2. Reinforce the points. Put a small strip of clear packing tape over each join, inside and out.
3. Seal it. A coat of Mod Podge or clear spray varnish helps light drizzle roll off.
4. Anchor it. Two bobby pins through the headband into your hair stop it blowing off.
5. Protect it on the way. Wear it there, or carry it in a big bag with nothing on top.

Felt, fabric or cardboard instead?

Want to know how to make a pirate hat out of felt or fabric? Use stiff felt with the same three-panel pattern and hot glue instead of staples. For fabric, glue it over a poster board hat. Learning how to make a pirate hat out of cardboard is the same tricorn method with a box cutter; it is heavier but nearly indestructible.

The hat is only one piece. Our guide to a pirate costume with regular clothes covers the rest, and you can pair it with an eye patch made from a bandana.

See your whole pirate look in two minutes

You now know how to make a pirate hat out of paper that actually fits. The Costume Rack takes care of everything under it: it matches your vibe and closet to the pirate costume, lists every piece with a version from things you own, and adds a one-piece-a-day countdown so the costume is ready by October 31.

Start my costume

FAQ

How do you make a pirate hat out of paper easy?

Fold a full double-page newspaper spread in half, fold the top corners to the center, fold the bottom flaps up on both sides and tape the corners. It takes about five minutes. For adults, never start from a single small sheet.

How do you make a tricorn pirate hat out of construction paper?

Tape two large sheets together, then cut three curved brim panels and a 2-inch headband sized to your head. Staple the panels to the band, fold them up and join their ends into three points. Poster board is sturdier if you have it.

How big should a pirate hat be for an adult?

The headband should match your head measurement (usually 21 to 24 inches) plus 2 inches of overlap. Each brim panel should be around 12 inches long and 5 inches tall. Measure over any bandana or wig you plan to wear.

How do you make a pirate hat out of cardboard?

Cut a headband strip and three curved brim panels from a flattened box, score the bottom of each panel so it folds up, then hot glue everything together. Paint it black and add a white skull on the front. It is heavier but survives crowds.

What else do I need for a pirate costume besides a hat?

A loose shirt, a sash at the waist, boots and maybe an eye patch. The Costume Rack lists every pirate piece and shows which ones you already own.