The first step in making a scale miniature cowboy hat is making a miniature hat form to shape it on.
- Measure the circumference of the hat stand or doll's head you want the hat to fit. Use a thread wrapped around the head, then measure the thread. Cowboy hats usually fit just above the ears, depending on the style.
- Determine the height of the crown of the hat style you want. Hats with a crease need to have a six inch crown to be able to sit on an average person's head, so a contemporary cowboy hat would need a scale version of the six inch crown, ½ inch for a 1:12 scale doll.
- Mark a distance equal to the scale crown height on your cork, with the narrow end of the cork facing up (so the top of the hat will be narrower than the base of the crown.) Check that the circumference of your cork at this line is close to the circumference of the doll head or hat stand you wish to fit.
- Carve a line around your cork at the point equal to the crown height. This will be the point you will place your twist tie, and a shallow line in the cork will help to hold it in place.
- Shape the top of the cork into the shape you want for a hat form. Round the top edge if you want a hat with a round crown, cut a V groove across the center of the cork if you want a contemporary cowboy hat with a crease down the center.
