Now for the hat!
This was done 'on the wing'....ie freestyle with just an idea in the head what I wanted it to look like, and no set pattern to go by other than a rough measurement of circumference of Clives head. I sewed the majority of it on my sewing machine...must admit it played along nicely and stitched the hessian like a dream...I wasn't expecting that, but am grateful it did, as this halved the time it would have taken to hand sew!
...you'll see why, next...
Those little triangle excess bit we snipped off? well this prevents too much excess material bunching up inside the brim and keeps it nice and flat.
...and four tall triangles of hessian fabric were cut. I had to calculate the base width of the triangle, taking into account seam allowance for each piece, x four to be just a fraction larger than the head circumference measurement. Better to err on the large size than to make a hat too small that will not only look to comical and silly, but be uncomfortable to wear.
Although not done at the time of wearing, I went on to cover the inside seam edge with a strip of cotton fabric. The raw hessian edge is very scratchy and itchy against the head...poor Clive bore it out for the night in question, but it was uncomfortable so I later went back and tidied up the seams.
Part 3 will cover the mask and hood.