First, I should say this block is only for preventing a wet hat from drying tapered, not for hat making.
It's rough-n-ready, easy to make and cheap.
First, on spare cardboard, I plotted an elipse that fitted snuggly inside the sweatband of my hat - so basically it's a section of my head.
I used the card to trace that elipse on a block of expanded polystyrene and cut the block straight down from that line using a bread knife.
I rounded the top By eye with the same knife.
Now, this shape was rough so I sandpapered it gently to a smoother shape.
Polystyrene is also soft so I built up a few thin layers of papier-maché using large strips of newspaper soaked in PVA glue.
This tightened as it dried to make a smooth hard surface.
Another bout of sandpapering and finally I water proofed it with a couple of coats of varnish.
This picture was taken before the final sandpapering so expect yours to come out smoother.
That's a neat idea, having a block especially for drying (but not blocking) a wet hat.
