Duct Tape Pirate Hat

Scallywags!  It's time to set sail in search of booty.  But every pirate be needin' a faithful hat.  And I got just the instructions for you.

Step 1: Materials

Time:
It will take approximately 2 hours to finish the duct tape pirate hat.

Materials:
2 rolls of black duct tape
1 roll of grey duct tape

Tools:
Door frame at least 18" wide
A head-sized and head-shaped object with which to build the crown around
Marker or Pen
Ruler
Knife or Scissors

Step 2:

Find a door frame that is at least 18" wide.  (Any frame at least 18" wide will work.)  This will be used to form the brim of the hat.

Step 3:

Add a strip of silver duct tape horizontally across the frame.  The tape shouldn't leave a residue if you work quickly.  If you are worried, you can put painter's tape on the door frame first.

Step 4:

Add another strip of silver duct tape across the frame below the first strip.  Overlap the strips by 1/4".

Step 5:

Continue adding strips until you have at least an 18"x18" square of duct tape.

Step 6:

Start adding strips of duct tape vertically across the horizontal strips.

Step 7:

Continue adding vertical strips of duct tape until you have at least an 18"x18" square of duct tape that is two layers of duct tape thick.

Step 8:

Continue adding layers of duct tape until you have at least an 18"x18" square of duct tape that is four layers of duct tape thick.

Step 9:

Add a final layer of black duct tape.

Step 10:

Carefully remove the five-layer-thick sheet of duct tape and lay it down on a table with the sticky side up.

Step 11:

Add a layer of black duct tape to the sticky side.  BE VERY CAREFUL.  If the sticky sides of two duct tape strips come into contact, they will be almost impossible to separate.

Step 12:

You should have a sheet of duct tape six layers thick that is black on both sides.

Step 13:

Draw a circle with a diameter of 18" in the center of the black sheet of duct tape.

Step 14:

Use a knife or scissors to cut out the circle.  Discard the outside scrap.  It is no longer needed.  Set aside the black duct tape circle.

Step 15:

Find something roughly head shaped and head sized.  I used two bowls.  Make sure whatever you use is larger than your head or the hat will not fit.  This will be used to form the crown of the hat.

Step 16:

Wrap duct tape around the outside of the bowl with the sticky side facing outwards.  Make sure the bowl is entirely covered.  This is the most awkward and hardest part of these instructions.

Step 17:

Add bits of black duct tape until there are no more exposed sticky sides.

Step 18:

Cut off any dangling bits of black duct tape.

Step 19:

Use the crown to mark a circle on the black duct tape circle.

Step 20:

Use a knife or scissors to cut out the smaller circle.  The black duct tape circle should now be the correct shape to become the hat's brim.  Discard the smaller black duct tape circle.  It is no longer needed.

Step 21:

Align the crown with the hole in the center of the brim.

Step 22:

Use small pieces of duct tape to attach the crown to the brim.

Step 23:

Fold the tape to form three small loops and put them evenly spaced around the brim.

Step 24:

Fold each of the three tape loops into the crown.  Enjoy your duct tape pirate hat.  YARRRRR!