How to Sew a Wirt Cosplay Hat: A Complete Step-by-Step Guide

Introduction to Wirt and His Iconic Hat

Wirt is one of the most beloved characters from Cartoon Network’s critically acclaimed miniseries Over the Garden Wall, a hauntingly beautiful animated story set in a mysterious autumnal forest called the Unknown. His distinctive look has made him a favorite subject for cosplayers worldwide, and no element of his costume is more recognizable than his tall, conical red hat. If you’ve already completed Part 1 of this cosplay series covering his cloak and tunic, you’re now ready to tackle the crowning jewel of the entire costume — quite literally. This guide will walk you through every detail of constructing Wirt’s hat from scratch, even if your sewing experience is limited.

The hat itself is a tall, pointed dunce-cap style cone rendered in a deep burgundy or brick red wool fabric, finished with a simple brim and a small decorative element at the tip. While it looks deceptively simple, getting the proportions right is what separates a truly screen-accurate Wirt cosplay from one that just approximates the character. The cone’s height, the brim’s width, and the fabric’s texture all contribute to how convincingly the final piece reads as Wirt’s hat when you’re wearing it at a convention or photoshoot.

Before diving into materials and construction, it’s worth taking some time to study reference images of Wirt from multiple episodes of the show. Pay close attention to how the hat sits on his head — it rests slightly forward and tilts at a gentle angle rather than sitting perfectly upright. This gives him his slightly awkward, melancholy personality through body language alone. Understanding these nuances will help you make small adjustments during construction that add up to a much more faithful final result.

Materials and Tools You Will Need

Gathering your materials before you begin is one of the most important steps in any sewing project, and Wirt’s hat is no exception. The primary fabric you’ll need is a medium-weight wool or wool-blend in a deep red, brick red, or burgundy color. Approximately half a yard to one full yard should be sufficient depending on your head size and how tall you want the cone to be. Avoid fleece or felt for the outer shell if you want a more authentic look, as these fabrics lack the slight structure and drape that wool provides. However, craft felt can be an excellent and budget-friendly choice for first-time cosplayers who simply want to achieve the silhouette without worrying about screen accuracy.

In addition to your outer fabric, you’ll need an interfacing material to give the hat its stiff, self-supporting shape. Craft-weight interfacing, buckram, or even a layer of stiff cardboard cut into a cone shape can serve as the internal structure. Many experienced cosplayers prefer to use a thermoplastic material like Worbla or craft foam for the interior skeleton because it allows for very precise shaping and can be molded using a heat gun. You’ll also need matching thread, fabric scissors, pins, a sewing machine (or needle and thread for hand sewing), and a flexible measuring tape to take your head measurements.

Here is a summarized list of everything you’ll want to have on hand before starting:

• Half to one yard of deep red wool or wool-blend fabric
• Stiff interfacing, buckram, or craft foam for internal structure
• Matching red or burgundy thread
• Fabric scissors and a rotary cutter with cutting mat (optional but helpful)
• Flexible measuring tape and a ruler
• Pins and sewing clips
• Iron and ironing board for pressing seams
• Hot glue gun (for attaching the tip embellishment)
• A small scrap of contrasting fabric or yarn for the tip decoration
• Millinery wire or thin armature wire for brim stabilization (optional)

[STUDIO_IMAGE: a flat lay of red wool fabric, sewing tools, scissors, measuring tape, and thread on a wooden craft table, warm overhead lighting]

Taking Measurements and Creating Your Pattern

The foundation of a well-fitting hat is an accurate head measurement. Use your flexible measuring tape to measure the circumference of your head just above the ears and across the forehead — this is the standard hat measurement known as your head circumference. Write this number down, as it will dictate the size of your brim opening and the base diameter of your cone. For most adults, this measurement falls somewhere between 21 and 23 inches, but always measure yourself rather than relying on averages, especially for a prominent costume piece that will be photographed from every angle.

To draft the cone pattern, you’ll be working with basic geometry. A cone is essentially a flat circle with a wedge cut out of it. The formula you need involves the slant height of your desired cone — how tall you want the hat to be when measured along its outer edge rather than straight up from base to tip. For Wirt’s hat, a slant height of approximately 14 to 16 inches creates a proportionate look for most adult wearers. Once you have your slant height and your base circumference, you can calculate the angle of the wedge to remove and draw your pattern on paper before cutting into any fabric.

For the brim, draft a simple donut shape — a circle with a hole in the center sized to match your head circumference. The outer diameter of the brim should extend about two to three inches beyond the inner opening on all sides, giving you a modest brim that matches Wirt’s design. Cut this brim pattern in two layers of your main fabric and one layer of stiff interfacing, which will be sandwiched between the two fabric layers. Don’t forget to add seam allowances of at least half an inch to all pattern pieces. Label each piece clearly before you cut to avoid confusion during assembly.

Constructing the Cone and Brim

Begin construction by cutting all of your pattern pieces from both the outer fabric and the interfacing. If you’re using a fabric interfacing, fuse it to the wrong side of one of each fabric piece according to the manufacturer’s instructions using your iron. For the cone specifically, you may want to cut the interfacing slightly smaller than the fabric piece to reduce bulk in the seam allowances. With your pieces cut and interfaced, fold the cone piece right sides together along the straight edges, aligning them perfectly, and pin or clip them in place before sewing a straight seam from the tip down to the base using a half-inch seam allowance.

Press the seam open with your iron — even on curved or conical pieces, pressing is essential for a professional-looking result. Then turn the cone right side out and check the shape. At this point you can adjust the seam if the cone looks too narrow or too wide for your liking. Many cosplayers also add a thin layer of batting or foam inside the cone at this stage to give it additional body and help it hold its shape throughout a long day of wearing. If you’re using Worbla or craft foam as your internal structure, this is when you insert that pre-formed cone shape into your fabric shell.

For the brim, place your two fabric pieces right sides together with the interfacing layer against the wrong side of one piece. Sew around the outer curved edge of the brim, then clip the curves generously to reduce tension before turning the brim right side out. Press it flat. The inner opening of the brim is left unfinished at this stage, as it will be sewn to the base of the cone during final assembly. If you want extra rigidity in the brim, you can hand-stitch a length of millinery wire just inside the outer edge before closing everything up, which will allow you to curve or adjust the brim’s angle after the hat is complete.

[STUDIO_IMAGE: hands carefully sewing red fabric on a sewing machine, close-up detail shot, soft natural window light from the left]

Assembling the Hat and Adding the Tip Detail

Now comes the satisfying step of joining the cone to the brim. Slip the base of the cone into the brim’s inner opening so that the right side of the cone faces the right side of the brim — essentially, the cone is pointing downward and the brim surrounds it like a ring. Align the raw edges, distribute the brim evenly around the base, and pin thoroughly. Sew this seam carefully, going slowly around the curve to maintain an even seam allowance. This is often the trickiest seam of the entire project, so take your time and don’t hesitate to baste the seam by hand first before committing with the machine.

After sewing, clip the seam allowance around the curve and press the seam toward the cone using the tip of your iron. Then fold the seam allowance under and topstitch around the base of the cone just above the brim to secure everything neatly. This topstitching also adds a subtle decorative detail that reinforces the seam and prevents it from flipping outward during wear. Try the hat on at this point to check the fit — it should sit comfortably on your head with the brim resting just above the ears. If it’s too tight, you can carefully remove the brim seam and let out a small amount of seam allowance to add circumference.

The tip of Wirt’s hat features a small decorative element — a subtle gathered or knotted piece of fabric or cord that creates a visual endpoint at the very top of the cone. This can be replicated using a small fabric-covered button, a hand-tied knot of thick cord or yarn, or a tiny gathered rosette of your main fabric. Attach this tip embellishment securely using a hand-sewn stitch or a dab of hot glue, making sure it’s centered perfectly on the point of the cone. This finishing touch is small but adds a great deal of character and signals to other fans that you’ve paid attention to every detail of the design.

Finishing Touches, Fitting, and Wearing Your Hat

With the main construction complete, take some time to do a thorough finishing pass over the entire hat. Check all of your seams from the inside to make sure they’re secure and that no threads are left dangling that could unravel over time. If you see any raw edges on the interior of the hat that might fray, apply a thin line of seam sealant or fray check liquid to prevent deterioration. Press the hat one final time with a steam iron, shaping the cone and brim carefully as you go. If your hat has a tendency to flop to one side, you can stiffen the cone further by applying a light spray of fabric starch to the exterior and allowing it to dry while the hat is supported in its ideal shape.

Comfort and wearability during a full convention day are just as important as aesthetics. Consider adding a thin strip of hat elastic or a ribbon tie beneath the brim that can be fastened under your chin or at the back of your head to keep the hat from slipping or blowing off. Another option is to sew a strip of soft foam or ribbon around the inner brim opening to create a sweatband-style interior that grips your head more firmly. Some cosplayers also add small hair clip attachments to the underside of the brim, allowing them to pin the hat invisibly to their hair for maximum security throughout the day.

When it comes to storing and transporting your finished hat, treat it like a real millinery piece. Avoid crushing or stacking other items on top of it. If possible, store it stuffed loosely with tissue paper or a small pillow form to help it retain its cone shape between wearings. For transport to conventions, a dedicated hat box or a large rigid container is ideal. With proper care, a well-constructed Wirt hat made from quality materials can last for many years and many conventions without losing its shape or color. The effort you’ve put into making this piece accurately and durably will reward you every time you step into character.

[STUDIO_IMAGE: a finished tall red conical cosplay hat displayed on a hat stand, dramatic studio lighting with a dark moody background]

Styling the Full Wirt Cosplay

Now that your hat is complete, it’s time to think about how it integrates with the rest of your Wirt cosplay. The hat is almost always seen worn at a slight forward tilt rather than sitting perfectly upright, which gives Wirt his characteristic hunched and somewhat reluctant posture. Practice wearing it at different angles in front of a mirror to find the placement that matches your reference images most closely. You may also want to style your hair flat and neat beneath the hat, as Wirt’s hair is dark and doesn’t add much volume that would change how the hat sits on the head.

Pairing the hat with Wirt’s other costume elements — his long burgundy cloak, white collared shirt, dark pants, and simple boots — completes one of animation’s most recognizable and beloved character designs. When photographed alongside a Greg cosplayer (Wirt’s energetic younger brother) and possibly a cosplayer portraying the Beast or the Woodsman, the full ensemble creates an instantly recognizable tableau that will delight fans of the show everywhere. Consider the lighting and setting of your photoshoot as well: Over the Garden Wall is a deeply autumnal story, so golden-hour outdoor locations surrounded by fallen leaves will elevate your photos dramatically.

Finally, take pride in the work you’ve done. Cosplay is fundamentally about celebrating the characters and stories that mean something to us, and Wirt’s hat is a beautiful, simple design that rewards careful craftsmanship. Whether this is your first sewing project or your fiftieth, the skills you’ve practiced here — drafting a cone pattern, working with interfacing, constructing a brim, and adding finishing details — are transferable to dozens of other costume projects. Share your progress photos in cosplay communities online, tag your inspiration sources, and most importantly, enjoy wearing the finished piece at your next event. You’ve earned it.