WOW! It’s nearly done now! Try it on your head to see how it fits!

If it fits like an Imperial hat, congratulations, you are now done sewing and pinning!
If not, you may need to start over. 


STEP #12 making an Imperial  GREEBLIE out of washers:


Roughen the bottoms of each of the three washers with a file. Brush off any excess filings.
Holding the 3 washers tightly together, take a pea-sized amount of silver sculpy III and fit it into the center of the washers. Keep the Sculpy center in place and bake the whole thing in your oven for 15-20 minutes @ 275 degrees. Remove. Allow to cool. Carefully pry the 3 washers apart with your exacto blade. It is easiest to leave the Sculpy center in the middle washer. Take a small amount of “GOOP” (or an other super-strong adhesive) and stick the three washers and the Sculpy center together being careful not to gopp excess GOOP all over the washers.

Or you may choose to purchase a hand-crafted machined aluminum greeblie. 
These are very high-quality and look just like the piece used on the movie screen. 
If you are interested in obtaining one of these, please send me an email.  

Find and mark the center point of the outside of the FRONT FLAP. Apply a little more GOOP to the back of your greeblie and viola! It’s DONE! FINALLY!

You have an Imperial hat.


Making this hat including making the pattern completely from scratch take me about 5 hours.
With the pattern, it takes me about 4 hours. Cost of materials (depending on what fabric you use) , around $10.
I get paid around $15 an hour at my job for doing things nowhere near as difficult as making this hat.
Imperial Officer's hat tutorial
steps 10-12
back to steps 6-9
back to Imperial Offericer's hat page one
I currently have an assortment of Imperial hats available in various sizes. 
Please contact me for further information
Here I am modeling the completed costume for the first time in January 2002
STEP #10 HAND SEWING.

Hand sew the lining in place using a tiny whipstitch every 1/8” all the way around. Remove the straight pins as you get to them.

STEP #11 ONE MORE LINE OF TOP-STITCHING

Turn out the VISOR and FLAPS again and sew an other line of top-stitching through all layers of the lining, flap, crown and visor seam allowances. This last line of top-stitching will not be visible in the finished hat and it will be going directly over the line of top-stitching you sewed around this part of the hat in STEP #8.