I have started patterning the core hat. My hat has three main parts. There is a brim, a side band, and a tip. The side band and the tip form to make a "bowl" that is attached to the brim.
Every good engineer knows to check their design. Yes, it will fit into the suitcase. =)
Making a brim requires a little geometry. It's all about centering and segmenting. It's hard to see.
I don't have a French curve big enough, so I used a stool and a bucket to get more precise curves.
Mr D helped by using a box cutter on the corrugated board. The box cutter is better than scissors on this material.
This duct taped, cylinder is NOT part of the hat. It's a hat form. It's a dress from for hats and will make constructing it much easier. Yes, I look demented. You would too, it's very tight fitting.
This is the side patterns with and without seam allowance. I hope you can see the folding on the paper that is required to taper the crown.
This is not going to be an Abe Lincoln stove pipe..but this just all the cardboard bits.
Cat Spam!