Crafting a Critter of Comfort: the Alligator Hat

Welcome, makers, to my very first Instructable! My wife and I recently embarked on a spooky and creative journey, transforming ourselves into characters from the beloved Haunted Mansion. As she prepared to embody the daring Tightrope Walker, a crucial element was missing: the lurking alligator beneath her. This sparked an idea to create a unique, lightweight, and comfortable alligator hat for our daughter to wear, completing our family's ghoulish ensemble. While our two-year-old model wasn't the most cooperative for a photoshoot, the hat itself is a testament to inventive costume design. This Instructable will guide you through the process of crafting your own charming (and comfortable!) alligator headwear, perfect for costumes, imaginative play, or adding a touch of reptilian whimsy to your day.

Here's what you'll need to bring your alligator hat to life:

1. 1 Large sheet of 3mm EVA Foam, Yellow (for the bottom jaw)
2. 2 Large sheets of 3mm EVA Foam, Green (for the top jaw)
3. 1 Small sheet of 3mm EVA Foam, White (for the teeth and eyes)
4. Hot Glue Gun (and plenty of glue sticks)
5. Cutting Tools:
6. Sharp scissors, or
7. Craft knife (e.g., X-Acto knife)
8. Optional: If you have access to one, a Glowforge laser cutter can significantly expedite the cutting process by precisely cutting your design files. (This is what I used to cut my pieces for a clean finish!)

To help you get started, I've created an SVG design file using Inkscape, a free and open-source vector graphics editor. This file contains all the necessary pieces for your alligator hat. Keep in mide this scale was for a two year old size head, you may want to scale up for an Adult.

Here's what you need to know about working with the SVG:

1. Color-Coded and Layered: All the parts within the file are color-coordinated to match the EVA foam colors we discussed (green for the top jaw, yellow for the bottom jaw, and white for the teeth and eyes). Each component is also clearly labeled in its own layer, making it easy to identify and work with individual pieces.
2. Duplication and Flipping: To create a complete, symmetrical head, some parts will need to be duplicated and then flipped horizontally. This is essential for creating both the left and right sides of the alligator's head, ensuring everything aligns perfectly during assembly.

You can open this SVG file in Inkscape or compatible laser cutter software to begin cutting your foam pieces.

Bow Tie Connectors: Your Secret Weapon for Strong Seams

In addition to the main alligator hat pieces, you'll find a second file titled "Bow Tie Connectors." This file contains three different sizes of bow tie-shaped connectors.

These little pieces are incredibly useful for reinforcing your hot glued seams. I recommend cutting a generous amount – aim for around 25 of each size. As you glue the main foam pieces together, especially when the shape is still floppy, these bow tie connectors can be glued over the seams on the inside. They work wonderfully to help hold the seams together and provide extra stability, allowing the hat to maintain its intended shape as the glue sets..

First things first, make sure you've **cut out all your EVA foam parts**. This includes the main body sections, the connecting tabs, teeth, eyes, eyelids, nostrils, and the tail. If you used a laser cutter, your pieces should be perfectly precise. If you're cutting by hand, take your time to ensure clean edges.

Begin by **attaching all the green top jaw pieces together** using hot glue. Work carefully, applying a thin bead of glue along the seams. Use the **connecting tabs** you cut out to help hold these floppy parts in place. These tabs will give the structure some initial stability until the glue dries and the shape becomes more rigid.

Next, **attach the yellow lower jaw pieces together** using the same hot glue and connecting tab method. You'll see the distinct shape of the alligator's head start to emerge.

I attached some pink inside the mouth just to add some support and color to the inside roof of the mouth.

With the main jaws formed, it's time to bring your alligator to life! **Attach the eyes** to the top jaw, followed by the **eyelids** directly above them. Then, carefully **add the nostrils** to the front of the top jaw.

Now for the crucial details! **Attach the white teeth** along the inside edges of both the top and bottom jaws. Finally, **add the tail** piece to the back of the top jaw.

Once all the glue has dried, grab a **black permanent marker (Sharpie)** and **draw in the eye pupils**. This will give your alligator hat personality.

Finally, **test your hat for a comfortable and secure fit**. You may need to make small adjustments, or consider adding an elastic chin strap if you find it's too loose, especially if it's for an active little one!

You can Add the small triangles to a shirt, and even create a tail to go under a Blue tu-tu to complete the look!