For your Donald Duck hat, you will need:
You'll also need a small piece for the "tail" at the top of the hat. I used scraps of quilt weight cotton; you really only need a little bit
Batting or Needlepunch: the same amount as your fabric. Not too lofty, as you aren't looking to pad the hat, just stabilize it.
Wide elastic: Black, at least 3 inches wide and long enough to go around the top of the recipient's head
A large button (optional)
Thread and your sewing machine
The first step is to measure the head of your recipient. Donald's hat sits at the top of his head, and you want the elastic to be snug. Ideally, you should try it on your recipient to be sure it fits. If you just have a measurement, I would use 1/2 to 1 inch less than the recipient's head.
Lap your elastic ends over one another and zigzag with a wide stitch over the seam, catching the raw edge in your stitching.
|Elastic with ends joined to form a ring|
|Measuring the larger circle|
|Your pattern, chalked onto main fabric|
Once you've cut out your circles (two of the main fabric and two of the batting), baste the main fabric circles to their corresponding pieces of batting around the outside edge.
|Circle basted and elastic joined|
|Main fabric tucked into inside out elastic ring|
|Batting still loose, elastic stitched to main fabric|
|Edgestitching around the elastic|
|Batting side, with the ring of edgestitching visible|
|Drawing the tail|
|The two pieces, ready to seam together|
|Seamed together, before turning|
|Ready for hand sewing|
Sew on your button through the main fabric and both layers of batting. This will help further stabilize that shape of the hat.