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The Magic Cafe Forum Index » » The workshop » » Mad Hatter's Hat Project Printer Friendly Version
Zazz

Veteran user
California
315 Posts 		Posted: Feb 14, 2010 4:36pm    Reply with quote   View Profile of Zazz  
I am building illusions to fit the theme of Alice in Wonderland for a new show for my daughter. The first thing I'm building is a Mad Hatter's hat reproduction for her to pull a rabbit out of. I am attempting to construct this out of fiberglass using a foam mold. The outside of the hat will be lined with tapestry.

I will post pictures as I progress.


Dan
Michael Baker

Inner circle
Near a river in the Midwest
8466 Posts 		Posted: Feb 14, 2010 5:40pm    Reply with quote   View Profile of Michael Baker  
Wow! I'm really looking forward to seeing that!
~michael baker
The Magic Company
JamesTong

Eternal Order
Malaysia
11210 Posts 		Posted: Feb 15, 2010 1:04pm    Reply with quote   View Profile of JamesTong  
The progressive pics would be interesting to watch. Looking forward to them too.
ringmaster

Special user
Memphis, Down in Dixie
996 Posts 		Posted: Feb 15, 2010 8:52pm    Reply with quote   View Profile of ringmaster  
You going to use Mark Wilson's hat, or Johnny Depp's?
I know it's spelled wrong.
http://s237.photobucket.com/albums/ff53/davidsweeney/Parker%20Jenny%20on%20Midway%20of%20Mirth/
Zazz

Veteran user
California
315 Posts 		Posted: Feb 15, 2010 11:11pm    Reply with quote   View Profile of Zazz  
Day number one of carving the foam form.

This is only the rough stage. The over-all size will shrink 1/2" all the way around and I may reduce the height by 3-4 inches. Height of hat in the picture is 20 inches and the head diameter is 12 inches.

Original Mad Hatter's Hat

Plywood Form Core

Attaching Core to Foam

Gluing the Foam

Gluing the Foam

Rough Carving

Rough Carving 2

Rough Carving 3

Rough Carving 4

Rough Carving 5
Michael Baker

Inner circle
Near a river in the Midwest
8466 Posts 		Posted: Feb 15, 2010 11:37pm    Reply with quote   View Profile of Michael Baker  
Great progress and great photos!
~michael baker
The Magic Company
Andrew H.

Regular user
Elizabethton,TN
123 Posts 		Posted: Feb 16, 2010 1:38am    Reply with quote   View Profile of Andrew H.  
WOW...Looks cool, your daughter should be very proud of you!
JamesTong

Eternal Order
Malaysia
11210 Posts 		Posted: Feb 16, 2010 1:05pm    Reply with quote   View Profile of JamesTong  
Great photos! Out of curiosity, what did you use to carve the foam so well and smooth?
Zazz

Veteran user
California
315 Posts 		Posted: Feb 16, 2010 1:35pm    Reply with quote   View Profile of Zazz  
I used a small hand saw for the bulk removal, a wood rasp for shaping and a Porter Cable detailer electric sander with 50 grit paper. I set the hat in a horizontal position and put a long dowel through the wooden core like a rotisserie. I rotated the hat by hand and sanded with the detailer sander similar to working a lathe. I still have a lot more sanding to do but I'm happy with the result of just one days work.

This type of project is new for me and I am grateful for this Workshop forum. I have gotten a lot of useful information from researching this site to start this project. I hope my trial and errors can help someone.

Dan
tabman

Inner circle
USA
5950 Posts 		Posted: Feb 16, 2010 4:47pm    Reply with quote   View Profile of tabman  
Looks like a fun medium to work with. Thanks for the pics and the progress updates. When sanding that foam with the Porter-Cable electric, is the foam dust any kind of a problem???
...Your professional woodworking and "tender" loving care in the products you make, make the wait worthwhile. Thanks for all you do...

http://Sefalaljia.com
Regan

Inner circle
U.S.A.
5440 Posts 		Posted: Feb 16, 2010 5:06pm    Reply with quote   View Profile of Regan  
Dan, this looks like it will be great! Just in time for the new Alice In Wonderland movie too!
Mister Mystery
Zazz

Veteran user
California
315 Posts 		Posted: Feb 16, 2010 5:10pm    Reply with quote   View Profile of Zazz  
Tabman,

I worked outside and wore a good dust mask, glasses and gloves. I didn't notice a lot of foam dust in the air, but I will pay more attention when I sand again and report if there is any difference.

Dan
Zazz

Veteran user
California
315 Posts 		Posted: Feb 16, 2010 5:18pm    Reply with quote   View Profile of Zazz  
Regan,

The Alice in Wonderland theme is something that my wife Kristen and Danielle have wanted to do for a couple of years now. Perfect timing that this movie is coming out and a new generation of kids will see it.

As I was collecting the material to start this project I was originally going to model this hat from one of the books pictures or from the Disneyland's ride and paint it a solid color. When I heard about the movie, I decided to make it look like Johnny Depp's hat.

Dan
Regan

Inner circle
U.S.A.
5440 Posts 		Posted: Feb 16, 2010 5:45pm    Reply with quote   View Profile of Regan  
Quote:

On 2010-02-16 17:18, Zazz wrote:

As I was collecting the material to start this project I was originally going to model this hat from one of the books pictures or from the Disneyland's ride and paint it a solid color. When I heard about the movie, I decided to make it look like Johnny Depp's hat.

Dan


Smart move!
Mister Mystery
tabman

Inner circle
USA
5950 Posts 		Posted: Feb 17, 2010 12:45am    Reply with quote   View Profile of tabman  
Quote:

On 2010-02-16 17:10, Zazz wrote:
Tabman,

I worked outside and wore a good dust mask, glasses and gloves. I didn't notice a lot of foam dust in the air, but I will pay more attention when I sand again and report if there is any difference.

Dan


Thanks Dan. Just curious about the foam dust. Seems like it could be wicked like plexiglass dust.
...Your professional woodworking and "tender" loving care in the products you make, make the wait worthwhile. Thanks for all you do...

http://Sefalaljia.com
Zazz

Veteran user
California
315 Posts 		Posted: Feb 20, 2010 9:18pm    Reply with quote   View Profile of Zazz  
Just got back from Tap Plastics with fiberglass supplies. This thing is not going to be cheap.

Dan
Zazz

Veteran user
California
315 Posts 		Posted: Feb 25, 2010 11:48pm    Reply with quote   View Profile of Zazz  
Quote:

On 2010-02-15 20:52, ringmaster wrote:
You going to use Mark Wilson's hat, or Johnny Depp's?


I'm going to try and build Johnny Depp's hat for this themed show. I made a Mark Wilson's Alakazam Hat last year for her. Here is a picture.

Mark Wilson's Alakazam Hat

Dan
tabman

Inner circle
USA
5950 Posts 		Posted: Feb 26, 2010 12:34am    Reply with quote   View Profile of tabman  
Great picture. I love the "hat."
...Your professional woodworking and "tender" loving care in the products you make, make the wait worthwhile. Thanks for all you do...

http://Sefalaljia.com
Zazz

Veteran user
California
315 Posts 		Posted: Mar 6, 2010 7:50pm    Reply with quote   View Profile of Zazz  
Started to epoxy fiberglass the hat today.

Dan
tabman

Inner circle
USA
5950 Posts 		Posted: Mar 6, 2010 9:33pm    Reply with quote   View Profile of tabman  
Great. Post some more pictures when you get a chance.
...Your professional woodworking and "tender" loving care in the products you make, make the wait worthwhile. Thanks for all you do...

http://Sefalaljia.com
Zazz

Veteran user
California
315 Posts 		Posted: Mar 7, 2010 12:00am    Reply with quote   View Profile of Zazz  
Below is a picture of the mold on the rotisserie. I just applied the Mold Release and one layer of glass. Tomorrow I will apply another coat of epoxy fiberglass.

Applying Mold Relase Agent

Dan
Zazz

Veteran user
California
315 Posts 		Posted: Mar 8, 2010 12:34am    Reply with quote   View Profile of Zazz  
I applied the second coat of epoxy fiberglass today. Next step after resin cures is to apply filler and sand.

Second layer of fiberglass

Dan
EsnRedshirt

Special user
Newark, CA
900 Posts 		Posted: Mar 8, 2010 10:04am    Reply with quote   View Profile of EsnRedshirt  
Must be a trick of perspective, but that hat almost looks big enough to pull a person out of (okay, maybe a small child...) How much do you estimate it will weigh?
Self-proclaimed Jack-of-all-trades and google expert*.

* = Take any advice from this person with a grain of salt.
Zazz

Veteran user
California
315 Posts 		Posted: Mar 8, 2010 11:23am    Reply with quote   View Profile of Zazz  
The hat is 20 inches high and the elongated part of the top of it is 20 inches. I haven't weighed it yet but it is not very heavy right now, even with the foam and plywood core.

Dan
RayBanks

Special user
Nassau Bay, TX
533 Posts 		Posted: Mar 10, 2010 12:36am    Reply with quote   View Profile of RayBanks  
I know you are probably real close to being finished but I ran across this for anyone else who might be interested.

http://www.instructables.com/id/Burtons-Mad-Hatter-Hat/
-------------
Pick a card, any card...No. not THAT one...THIS one

Ray Banks
Regan

Inner circle
U.S.A.
5440 Posts 		Posted: Mar 13, 2010 6:13pm    Reply with quote   View Profile of Regan  
Looking good Dan! Danielle is very lucky to have a father that can....and that is willing to build all these nice props for her!

Regan
Mister Mystery
Zazz

Veteran user
California
315 Posts 		Posted: Mar 13, 2010 11:18pm    Reply with quote   View Profile of Zazz  
I enjoy building them. I am lucky to have a daughter that uses the things I build for her and a wife that creates routines for them.

Here are a few more photos:

Hat Filler 1


Hat Filler 2


My daughter, Danielle, just had an article in the March edition of The Linking Ring magazine. It turned out really great. Please ready if you have time. Here is a thread with a link to the article.

Surprising Young Lady

Dan
Regan

Inner circle
U.S.A.
5440 Posts 		Posted: Mar 14, 2010 4:08pm    Reply with quote   View Profile of Regan  
Dan, that was a nice article! Congratulations to Danielle! (And to you and your wife too). I had not put it together until I started reading the article when I received my Linking Ring magazine this past Friday, but I remember when Danielle first started performing magic. You or your wife had inquired about some sort of routine (may have been a patriotic theme) for your daughter. We emailed (or PMed) back and forth about it. She was going to perform for her ring I believe. It was several years ago, and I think Danielle was just a little thing at the time. Wow.....I can't believe how far she has come. I'm thankful to know she really stuck it out! It's good to finally realize who you all are. I knew you, but I did not really know your association with one another.

Regan
Mister Mystery
Zazz

Veteran user
California
315 Posts 		Posted: Mar 15, 2010 12:35pm    Reply with quote   View Profile of Zazz  
Regan,

Thanks. People like you and others on this forum have really helped us through the years with suggestions and support. Magic is one of the things the three of us really have in common. It helps bring us together.


The next 2 months are going to be busy at work. Lots of O.T. on the weekends. I am going to have to use evenings after work to make progress on this Mad Hatter's hat. This and three other illusions need to be made for her new show. I hope I can get it done.

Dan
Regan

Inner circle
U.S.A.
5440 Posts 		Posted: Mar 16, 2010 9:52am    Reply with quote   View Profile of Regan  
Quote:

On 2010-03-15 12:35, Zazz wrote:
Regan,

Magic is one of the things the three of us really have in common. It helps bring us together.

Dan


Dan, I know what you mean. My wife and I have only one daughter, and we perform together (magic & music). I feel really blessed to be able to do it as a family.
Mister Mystery
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