Make your own Shako

1. Make the base: measure the circumference of your skull at the point where the Shako will sit, add 1 inch for a seam allowance.

2. Draw a line of this length across a piece of cardboard or thick card. 8 inches up from the first line draw a parallel line that is 2 inches longer. Make sure the centre of the line is in line with the first.

3. Connect the ends of the first and second lines to make a trapezoid shape.

4. Cut out the shape, roll the flat piece into a cylinder and lay one edge over the other with a 1 inch overlap. The top should be slightly wider than the base.

5. Glue the overlap in place and allow it to dry completely.


6. Add a top, flip the hat base over so that the wider end rests on your cardboard. Trace around the outside of the hat.

7. Draw a second concentric circle that is about 1/2 an inch larger than the first and cut along the large circle.

8. Make small cuts inward from the edge of the circle to the first line. Continue around the edge of the circle.

9. Fold the cut tabs down. Slip the circle over the top of the hat base with the tabs inside the hat, glue the tabs to the inside of the shako so that the stop is level.


10. Cover the hat with a piece of felt or leather which will fit the whole exterior.

11. Wrap it around the base and glue it in place along the seam, cut a circle of the same fabric to fit the top of the hat and glue it down.

12. Place the narrow end of the hat base on your cardboard and draw the shape of the brim.

13. Remove the hat and add a 1/2 inch allowance to the inside of the brim.

14. Cut out the shape and use a pair of small scissors to clip the extra allowance as you did with the top of the hat.

15. Cut a piece of material to match the shape of the brim, minus the clipped session. Add about 1 inch extra long the front edge.

16. Glue the piece of brim, minus the clipped section. Add about 1 inch extra along the front edge.

17. Glue the piece onto the brim and fold the extra fabric under the bottom edge.

18. Cut a section piece of felt to the exact brim size and glue it to the underside of the brim to cover the folded material.

19. Place the brim on the hat base and fold the tabs up to the inside of the hat. Glue the tabs in place.

20. Glue a trim on such as braided leather, glue a section of trim around the top edge of the hat base.

21. Position the trim so it hides the seam between the base and top.

22. Glue another section around the base of the hat to cover the rough edges. If you like you can also put trim around the brim or the side of the hat.