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My son wanted a "Gilgamesh Wulfenbach shmott guy!' hat from the Girl Genius webcomic for crazy hat day at school, how could I refuse.
materials used:
- baseball cap
- poster board
- foam board
- paper mache
- polyester batting
- fabric
- felt
- spray paint
- titebond wood glue
- more mini glue sticks than you would think possible
- wires, a switch,LEDs,a small DC motor, and an 18650 cell from an old laptop battery

The base
the spiky things on the side before painting. they are paper mache formed in parts over aluminum foil molds
the mid section before covering it with polyester batting and fabric, this is all foam board
the top section built on a foamboard cone, you can see the score marks on the back side that helped it be formed into shape
and the finished hat
I thought I had some pictures of the blower assembly for the "flame" but I can't seem to find them