The following is directions on how to make a tricorn hat from cheap materials that can be found at your local fabric store and even some wal-marts.
Felt (wool would be awesome but i just used the regular craft stuff)
needle and thread
ribbon or bias tape
First measure your head circumference and find a bowl or a ball that has a slightly larger circumference. This will be your hat form. I used a bowl.
Next cut two pieces of felt that are large enough to be pulled down over the hat form. Run the first piece of felt under the facet until it is soaked. Stretch it over the hat form and secure it with a rubber band. Keep tugging on the felt until you get it as stretched as possible. Let the cloth dry for a few hours. It doesn’t have to be dry just make sure it’s not soaking. You could seed up the process by putting it under a fan.
Next, cover the hat with glue and stretch a second layer of wet felt over the hat securing it with the same rubber band. Let the hat dry completely.
Trim the hat to about an half inch below the rubber band.
to make the brim of the hat cut two large circles of felt. then cut a hole in the center about a half an inch smaller in diameter than the hat for.
take the hat off the hat form and place it on top on one of the circles centered above the hole. Put the other circle on top of the hat and gently pull it down. Stitch the two circles together at the opening, catching the hat in the middle.
Glue the to circles together forming the brim of hat. Pin the ribbon or bias tape along the edge hat and sew. (I think bias tape would work better.)
If the brim of your hat has dried so that you can’t bend it get it damp until you can. position it with three edges up and pin it. let the hat dry. Try it on and you’re done!