![]() I sewed it up the way it was, trimmed the seam allowance very close to the seam, re-inverted the hat and did another seam. Before I sewed the hat together, I took one last look and realized that I had pinned the inner cone in inside out! Horror! I was going to have to pin it again, or the seam allowance would be on the outside of the hat. This was complicated by the fact that I was also pinning in a hat band, so the actual pinning was stupidly time consuming. Making the inner cone was trivial, but attaching the brim cone piece at just the right position so it wouldn’t kink the inner cone ended up taking three attempts. I had designed the hat with two intersecting cones of paper. ![]() Thankfully, the belt loop was big enough to double as the sword loop and the dragging sword crisis was averted. I should have double-checked the sword loop height because that ended up being a bit low, and the sword was going to be dragging its tip. I’m not even sure what that’s called on a cloak. The only things I put on the cloak above the bare minimum were some belt loops, a sword loop, and an extra layer across the back in the shoulder blades area. I cut, pinned, sewed, and hemmed like crazy. The advantage of working at home was I could actually size the thing to Pioneer’s body instead of snagging a shirt/pants and sizing from that. Ok, there were also two piece of paper for the hat. One was for half of the arm and another for the back, which doubled as the front sides. So working upstairs wouldn’t be that much of a step down, and hopefully I wouldn’t have to iron. I still use my own sewing machine because that’s what I’m used to. TechShop is awesome for sewing projects because I can spread out on three tables and there’s good lighting and an ironing board and iron. I set up a folding table in the guest bedroom to act as my sewing room so I wouldn’t have to commute over the hill to TechShop. ![]() So it was strictly an evening of Design & Build. Thankfully, I’d already purchased the fabric to make the costume. ![]() I couldn’t even work late into the night because I was still recovering. In the end, I had to design and sew together Pioneer’s Gandalf hat and cloak in 4 hours on Halloween Eve. In the run-up to Halloween, I’d spent most of my time working on Simon’s King Cobra costume, and then I got sick. I had made Gandalf’s sword, but I still needed to make his cloak and hat. Pioneer wanted to be Gandalf The White for Halloween. ![]()
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