How to Store Hats. When storing hats for long periods of time, it's essential to keep them protected from everything from humidity to sunlight, mold and dust. You also want the storage for your hat to fit it perfectly. To that end, making a custom hat box is one of the best storage methods.
Measure the hat at its widest points and add one inch to the measurement. Measure the height of the hat and add 1/2 an inch.
Draw two circles on a piece of poster board with a diameter matching the width measurement for the hat. The distance from one side of the circle to the opposite side of the circle should match your measurement. You can use measuring tape to set the points on a compass at half of the width measurement.
Draw two more circles on the poster board that are 1/4 inch bigger than the first two circles. These two circles should be the exact same size.
Cut out two strips from the poster board that match the length in the circumference of your smaller circle. Find the circumference of the circle by multiplying 3.14 times the diameter of the circle. The width of the strips should equal the height measurement of your hat (plus the 1/2 inch).
Cut out two strips of poster board 1 1/2 inches wide with a length matching the circumference of the larger circle.
Glue the two smaller circles together, the two larger circles together and the matching strips. You should end up with one smaller circle, one larger circle, one wide strip and one 1 1/2 inch wide strip.
Cut out two more strips from the poster board that are 32 inches long and 1 1/2 inches wide. Cut these strips into 4 inch long pieces. You should have a total of 16 pieces. Fold 8 pieces in half lengthwise and fold 8 pieces lengthwise at the 1 1/2 inch mark.
Glue the 8 strips folded in half to the smaller circle so that the fold is on the outside of the circle. Space the strips evenly around the circle. You should have one side glued down and another side sticking up at the outer edge of the circle.
Wrap the widest strip of poster board around the small circle with the tabs on it. Make sure the length of the poster board matches the circumference of the circle. Staple the ends of the strip together to form a circle. Glue this strip to the tabs on the circle. You are forming the bottom and side of the box.
Follow the same process of adding the folded strips to the larger circle, making sure the 1 1/2 inch portion sticks up from the circle. Wrap the 1 1/2 inch wide strip around the circle to match the circumference of the circle and staple it together. Glue the strip to the tabs to create the lid for the box.
Cover the box with Modge Podge to make the box washable and decorate the box with fabric.