The Midnight Cone: Crafting a Whimsical Witch Hat

A swift and sparkly sew—perfect for last-minute witches with a secret sunny base

Looking to conjure up a witch hat with a twist—literally? This enchanting project transforms an ordinary summer hat into a whimsical, sculptable topper using felt, feathers, and just a dash of magic dust. With only a few stitches and sparkles, you’ll whip up a hat worthy of midnight mischief and moonlit broom rides. Best of all, it's beginner-friendly, swift to make in a single evening, and includes steps for drafting a custom pattern to fit any hat—no spellbook required!

1. 1 wide-brimmed summer hat for the base (50 cm in diameter used in this tutorial)
2. Black felt fabric (enough for two 50 cm brim circles and two 55 cm tall cone pieces)
3. Sewing thread in a matching color (plus a thick thread for gathering the cone base, optional but helpful)
4. Real feathers, feather boa, and synthetic flowers (can be painted to your desired shade)
5. Additional trim: ribbon, lace, glitter, or decorative fabric scraps
6. Chalk or fabric marker
7. Large sheet of paper for pattern drafting
8. Scissors and pins
9. String, or sturdy thread (for compass drawing method)
10. Sewing machine or hand-sewing needle
11. Hot glue gun (optional, for attaching embellishments)
12. Masking tape (for holding patterns or stabilizing paper while drawing)

Choose a lightweight but trusty summer hat with a nice wide brim—this will be the hidden heart of your magical creation, making it both comfy and sturdy enough for every broom ride.

I chose to use a summer hat I already had and loved—it was important to me to build on something familiar and comfortable. It also made the whole project easier to shape, and easy to undo or adjust later if needed.

Place the hat on a large sheet of paper and trace around the brim, adding an extra 1 cm all around. This slightly larger felt cover gives you more room to maneuver and ensures a smoother fit. Fold the circle in half twice to find the center and mark the crossing point.

Now, measure the diameter of the part of the hat that rests on your head—this is where the cone will perch. Add 2 cm to that measurement to make space for thick felt and a bit of wiggle room. For this hat, the final measurement becomes 22 cm.

Use that number to draw a smaller circle in the center of your traced brim—this will become the opening for the cone.

Now for the cone! Decide how tall you'd like your hat’s peak—I went with a proud 55 cm. To draw it, imagine a triangle with a gently curved base. Here’s the magical trick: that curved base must match the circumference of the inner opening you just created. Since the inner diameter is 22 cm, the arc for your cone should be about 69 cm.

To find that, use the formula:

Circumference = π × diameter

Circumference = π × 22 ≈ 69.1 cm

To draw it: tie one end of a thick thread to a pencil, and hold the other end at 55 cm from your marked point. Sweep it like a compass across your fabric or paper to create an arc. Secure your paper with masking tape if needed to keep things steady. Then measure along the arc until you reach 69.1 cm of swirling magic. Mark both ends and connect them back to the center to complete your cone segment.

Cut two of the big enchanted fabric circles. Be sure to add a little extra around all edges for your seam allowance—this magical margin will help when stitching the circles together or attaching the cone on top. Leave a generous amount of fabric in the center as well—we'll simply clip it at even intervals later to ease the curve.

Sew the two circles together along the outer edge, leaving the center hole open for now. Flip the piece right-side out so the seams are neatly tucked in. Lightly redraw the inner circle to guide your stitching when attaching the cone. Then, gently slide the felt brim over the summer hat like a magical sleeve. Using a steady hand—or a well-practiced patience charm—stitch the inner circle of the bottom layer securely onto the crown of the hat, right along the edge. This is where your brim becomes part of the hat's secret structure!

Leave a little extra room around the edges of your cone pattern pieces—this will be your seam allowance for sewing the layers together and for attaching the cone to the brim. Cut two of these enchanted pieces—together, they'll form a strong, moldable cone with a bit of charm.

Sew the two cone pieces together along the sides, keeping the curved base open. Flip it right-side out to hide the seams and give your cone that magical structure. For an extra touch of practicality, I stitched a thick thread along the base seam—this makes it much easier to secure the cone to the brim. You can even tie the thread in a gentle knot to help gather or shape it just right before final stitching.

Once it’s ready, center it on top of the hat’s crown and pin it in place. Stitch it down with firm, even stitches all the way around. Don’t worry about perfect lines—this join will be delightfully concealed beneath feathers, florals, or your choice of spellbinding trim.

Give your faux flowers a dramatic enchantment—paint them black for that moonlit mystique, or charm them in a hue that suits your spellwork. Stitch them around the base of the cone, along with real feathers, ribbon, or scraps of fabric to conjure a flourish of personality. For extra hold or a layered effect, a dab of hot glue can lend a helpful hex—but I prefer to stitch everything in place. It keeps the hat soft and moldable, perfect for reshaping as the mood strikes.

Give your hat its signature twist! Gently curl or bend the cone into whatever whimsical shape your witchy heart desires. Thanks to the double-layered felt, it will hold its form all on its own—no wire needed. For a more dramatic or stubborn curl, you can use a few discreet safety pins to tuck and secure it in place until your hat’s curl is charmingly crooked—or devilishly dramatic.

Sprinkle on a final bit of razzle-dust or moon shimmer—glittering powder or shimmer dust works like a charm! I chose a dash of green, the color of my favorite bubbling potion. Now your one-of-a-kind, sculptable witch hat is ready to steal hearts and cast shadows under any moonlit sky.

1. Use different felt colors: forest green, deep purple, or midnight blue
2. Add lace trim, glitter, or embroidery
3. Sew in LED fairy lights for a glowing magical effect