How to Make a Beer Box Cowboy Hat

Cowboy hats made out of empty beer boxes are available online and at the superstores. These gags require you to pay a decent cost for purchasing. However, you can make use of your creative skills to make your beer box hat at home. These sort of fancy hats look great, especially when you have to go out in sun. You will need to have two empty beer boxes and they can be easily found if there has been a party of adults!

Things Required:

– 2 empty 24-can beer boxes
– Marker
– Packing tape
– String
– Stapler
– Scissors or any other appropriate cutting tool


  • 1

    You have to flatten the two beer boxes to begin. Cut open both ends of the 24-can beer box, keeping the printed side of the box towards the floor.

  • 2

    Entirely flat the two boxes after opening them up. You can press the boxes with your bare hands or use a heavy book to make them flat uniformly.

  • 3

    Take measurement of your head by wrapping a piece of string around it. Make sure to choose the largest part of your head to take the measurement and then mark the diameter of your head on the string with a marker.

  • 4

    Now take the string and place it on one of the flat cardboard pieces, making an oval shape to represent the size of your head.

  • 5

    Use a marker to draw an outline of the oval made by the string. This will be the size of the cowboy hat you are about to make. Use scissors to cut the cardboard around the tracing you made from the marker.

  • 6

    Next comes the step of making the brim of your hat. Draw another oval shape about 3 inches from the boundary of the cardboard you just cut out. Cut the bigger oval from the cardboard and this ring shall become the brim of your beer box hat.

  • 7

    The second flat box will be used to make the body of the hat. Cut a 4-inch wide strip from that piece of cardboard and you must ensure it will be long enough to encircle the circumference of your head.

  • 8

    Now you just have to assemble the three pieces of cardboard together to form your cowboy hat. Staple the two ends of the cardboard strip to make a hollow cylinder.

  • 9

    Fold ½ inch from the edge of the hollow cylinder from the top and the bottom. Place it on the oval ring and then put the hat top upon the folded side of it. Now carefully secure the three pieces using clear packing tape. This will make your bear box cowboy hat for free!

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