Guide to Making a Beer Box Cowboy Hat

Use Empty Cardboard Cases of Your Favorite Beer Brand to Make a Cowboy Hat

Jessie Kay
Seen at college frat house parties, sporting events and bars, cowboy hats made out of beer box cases are everywhere. Novelty shops sell beer box cowboy hats, but why spend money on something you can make from supplies you already have around your house? Even if you don't have the necessary beer box cases, this is a great excuse to head down to the liquor store and guzzle a lot of beer.

Before you begin, you'll need three beer box cases (should be a 18-pack size or more), scissors, compass, pencil, stapler and a long shoelace.

Step 1: Break down the three boxes by unfolding at the seams. Flatten the boxes as much as you can. If the boxes are still lumpy, use a heavy book to run over the seams to smooth it out.

Step 2: Use a shoelace to measure the circumference of your head. Wrap the shoelace around your head and note the spot where the ends come together.

Step 3: Take one of the boxes and turn it so the printed side is down. Put the shoelace in a circle (create this by using your measurements) in the center of the box. Using a pencil, trace the circle and cut it out. This will be the top of your hat.

Step 4: Grab another box, place it face-down. Put the cut-out circle in the center and trace with a pencil. Stick the compass' point in the center of the circle and expand it about three inches from the edge of circle's outline. Trace using the compass. Take your scissors and cut along the outer circle's outline. Then, cut out the inner circle. This creates a ring for the hat's brim.

Step 5: Using the last box, start cutting strips that are about four inches long and six inches wide. These strips are used to attach the top of the hat to its brim using a stapler. The amount of strips needed depends on how large your hat is.

Step 6: Shape your hat, cowboy-style. Bend the front rim up and roll in the side. Place a dent in the top hat to mimic a cowboy hat.

Step 7: Poke a tiny hole on each side of the rim. String your shoelace through the holes to create a chin strap.

Step 8: Put your beer box cowboy hat on and let the drunken debauchery begin!

Published by Jessie Kay

Missy Jess enjoys writing about video games, home improvement tips and travel articles. In addition to writing, she enjoys long-distance running and fitness.  View profile

5 Comments

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  • Kirstin Filliez4/5/2010

    I'm gonna make my hubby one for his birthday...

  • Lisa Kinney3/27/2010

    This is funny!! I think I will wear one to my next summer cook out!

  • M.G. Hardiman3/26/2010

    Too funny!

  • Millionaire Hoy3/26/2010

    Showing Page View Love :)

  • Ranee Wright3/25/2010

    Too funny! Fabulous how-to.

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