How to Make a Witch Hat Out of Cardboard (Adult Size)
Here is how to make a witch hat out of cardboard in adult size: measure around your head, cut a large quarter-circle from poster board or flattened cereal boxes and roll it into a cone that fits that measurement, then cut a ring-shaped brim about 4 inches wide and attach it with tabs. Cover it in black paper or fabric and add a band and buckle. Plan on about 45 minutes.
If you have the hat covered but not the rest of the witch, The Costume Rack builds the full look from your closet, piece by piece: Start my costume.
What you need
- Cardboard: one large sheet of black poster board (about 22 x 28 in) is easiest. Two or three flattened cereal boxes taped together also work.
- A string and pencil (a homemade compass)
- A soft measuring tape or a piece of string and a ruler
- Scissors and a craft knife if an adult is helping
- Strong tape (packing or duct tape) and hot glue
- Covering: black paper, black fabric, black felt or black paint
- Band: ribbon, a strip of fabric or felt, plus a buckle cut from card or foil
- Optional: bobby pins or thin elastic to keep it on
Measuring your head
Most kids' craft hats fall off adult heads because nobody measured. Do this first.
- Wrap a measuring tape around your head where a hat would sit, just above the ears and across the forehead.
- Write down the number. Most teen and adult heads are roughly 21 to 23.5 inches around.
- Add half an inch for the covering and comfort. That is your fit number.
Keep this number handy for the cone and the brim.
Cutting the cone from cardboard
Draw the quarter circle
- Tie a pencil to a string about 16 to 18 inches long.
- Hold the string end in one corner of the poster board and swing the pencil in an arc. Cut along it.
- You now have a big quarter-circle. The curved edge becomes the bottom of the cone.
Roll and fit
- Roll the piece into a cone, overlapping the straight edges.
- Put it on your head and adjust until the opening matches your fit number.
- Mark the overlap, take it off and tape the seam firmly inside and out.
- Trim the bottom edge so the cone sits level.
Taller or shorter? A longer string makes a taller hat. 16 inches gives a classic height; 20 inches gives a dramatic storybook hat.
Make it bend
For that crooked witch-hat tip, squeeze the top third gently and bend it to one side. Tape inside to hold the kink.
Making a brim that does not flop
The brim is where cardboard hats beat paper ones. It should be stiff and flat.
- Trace the bottom of your cone onto cardboard. That is your inner circle.
- Draw a second circle about 4 to 5 inches outside it. That is the outer edge.
- Draw a third circle 1 inch inside the inner circle. This strip becomes tabs.
- Cut out the outer circle, then cut out only the smallest circle.
- Snip from the center hole to the inner circle line every inch to make tabs.
- Fold the tabs up, slide the cone down over them and hot glue the tabs inside the cone.
Anti-flop tricks
- Use two layers of cardboard for the brim with the corrugation lines crossing.
- Glue a ring of thin wire or a coat hanger along the outer edge (adult help needed).
- Give the front of the brim a slight downward curve for a classic witch shape.
| Material | Brim strength | Weight | Covering needed? |
|---|---|---|---|
| Black poster board | Good | Light | Optional |
| Cereal box | Good | Light | Yes, it has print |
| Corrugated box | Very strong | Heavier | Yes |
| Paper only | Weak | Very light | Needs doubling |
A hat is one piece. A witch costume is five or six, and that is usually when the planning gets messy.
The Costume Rack lists every piece of your witch for you, from the dress to the shoes, with a "Find it" link for anything missing, a version from your closet, and a no-makeup build. A one-piece-a-day countdown to October 31 keeps it on track. Start my costume
Covering it with paper or fabric
Paper covering
Wrap black paper around the cone and glue it, overlapping the seam at the back. Cover the brim top and bottom separately. This is the quickest way if you are wondering how to make a witch hat out of paper-style finishes on cardboard.
Fabric covering
Black felt or cotton looks the most finished. Cut the fabric using the cardboard pieces as a template, with a half-inch border. Glue it on, snipping the edges so they fold neatly.
Paint
Two coats of black acrylic. Easy on poster board, streaky on printed cereal boxes unless you prime with white first.
If you would rather sew a soft hat, a how to make a witch hat out of fabric pattern is a different project. This cardboard version holds its shape better and needs no sewing.
Adding a band and buckle
- Wrap a 1 to 1.5 inch ribbon or felt strip around the base of the cone. Glue at the back.
- Cut a square buckle from gold card or foil-covered cardboard. Cut a smaller square out of its middle.
- Glue it to the front of the band.
Other finishing touches
- A fake spider or bat on the brim
- A few dried leaves or fake flowers tucked into the band
- Purple, green or orange ribbon for a colored witch
Keeping it on
Glue two thin elastic loops inside the cone and pin them into your hair, or tie a thin elastic under your chin.
Finishing the witch look
How to dress up as a witch for halloween with closet pieces:
- Witch costume women: a black dress or skirt, striped or black tights, boots and a shawl
- Witch costume for guys: black pants, a dark shirt, a long coat or cape and the hat
- Cosy witch: a long black cardigan over everything
- Glam witch: dark lipstick and a velvet top
The hat also works on a tutu witch (see Halloween costume with a tutu) and is great for a coven; our teen trio ideas include a witch, black cat and pumpkin set.
Your witch, planned in two minutes
Now you know how to make a witch hat out of cardboard, finish the rest just as fast. The Costume Rack matches your vibe and closet to the witch (or one of fifteen other costumes) in about two minutes, lists every piece and where to find it, and your friends can claim their looks from one group link so nobody clashes.
FAQ
How do you make a witch hat out of cardboard for an adult?
Measure your head, cut a quarter-circle from poster board with a 16 to 18 inch radius, and roll it to fit. Add a 4 to 5 inch brim attached with tabs, then cover and decorate it.
How do you make a witch hat brim stiff?
Use two layers of cardboard with the lines crossing, or glue thin wire around the edge. Poster board is stiffer than paper, and cereal boxes are a good free option.
Can you make a witch hat out of a cereal box?
Yes. Flatten two or three boxes, tape them together for the cone, and use another for the brim. Cover with black paper or paint since the print shows through.
What can I wear for a DIY witch costume without a hat?
A black dress or outfit, a long cardigan or cape, striped tights and dark lipstick all read as witch. A broom prop helps a lot if you skip the hat.
How do you keep a witch hat on your head?
Glue thin elastic loops inside the cone and pin them into your hair, or add a chin strap. A hat made to your head measurement also stays put much better.