Ventured into hat making for a Star Wars costume made for my kid. I grabbed the Star Wars Imperial Officer Hat pattern from cyberseams.com. Janet's pattern was amazing! I loved the specific brand recommendations for interfacing, and I also liked that she used actual sewing terms with explanations where a noob like myself might fall down. All my questions were answered by googling when I got stuck.
We have abnormally large heads in this family, so I splashed out with enough material for two. Most of it was available from JoAnn's. My partner sews more than I do, and she helped me make sure I had all the seam allowances and backing correct before I started cutting.
The top and crown was where I struggled the most. It kept bunching up and puckering, and I couldn’t figure out a way to get it to stop. I just lived with it once I fixed the worst spots, and you can’t see it from 10 paces. Especially on black! After finishing the cap, I found that the instructions say to cut relief snips along the seam allowance of the top. Rookie mistake that I should have realized once the puckering started. Better luck with round two!
