This bad boy took about ten hours of construction. I started with a plain straw hat from Michael's Arts & Crafts and, using this tutorial as a jumping off place, I covered the crown, outer brim, and inner brim with cotton fabric left over from a waistcoat I'd made for my beau. I covered the joints around the base of the crown and just under the brim with braided gimp. I then sewed one side of the brim to the crown, hiding the stitches in the gimp.
That was an absolute pain in the keister, let me just say. There was SO MUCH dried glue that I had to sew through. I needed a thimble to push the needle in and then small pliers to pull the needle out on the other side.
Eventually, I felt that the connection was secure and moved on to lining the inside of the crown with scraps of black linen. I covered the transition join between linen and cotton with another length of gimp. At this point, I'd been working on the hat for about four hours and was too pooped to continue. ( Feathers would wait until the next evening. )