The hat makes the man or lady, for some Moroccan chic read on for instructions on how to make your own Fez.
One small piece of regular felt for the top of the fez.
One piece of stiff felt (or regular felt if you prefer) for the body of the fez
thread and needle
small tassel (purchase or make your own with braided nylon cord)
Initially, I must note that although this pattern fits Lucius, it may need slight adjustments or improvements to fit your needs. Therefore, first, measure the circumference of your companion's head. Lucius' head is approximately eight and three-quarter inches in circumference. If your subject's head is larger or smaller, you will want to take that into consideration when cutting the pattern.
Second, right click on the picture to the right and save a copy of the picture. Next print your saved copy. The printed copy should be full size. Then cut the pattern out, adjusting as needed. You may wish to rough fit the paper pattern to your compatriot's head to make sure of the fit before cutting the felt.
Third, cut out your felt using your pattern. I prefer using stiff felt for the body of the fez as it holds its shape better. However, I prefer to use regular felt for the top of the fez because I feel that a more malleable fabric is required.
Fourth, wrap the long piece of felt (the body of the fez) around your friend's head and use several pins to fix the two ends of the felt together where you wish to sew them. At this time, make sure the conical angle of the fez is to your liking. Sew the two ends together leaving the top quarter inch free. Eventually, the top quarter inch of felt will be folded inside the fez and will be sewn to the top of the fez. If necessary, cut away any final excess felt.
Fifth, turn the body of the fez inside-out. Bend the top quarter inch of felt outward. You will need to make a few cuts in the felt so that it folds outward properly (three or four should be sufficient).
Sixth, take the top of the fez and lay it on top of the folded down quarter inch and pin the two pieces together. Remember that once the top of the fez is sewn on, you will turn the fez right-side out again. Therefore when placing the top of the fez onto the body, place the side that you want to show on the bottom.
Seventh, sew the body and top of the fez together by stitching the folded down quarter inch to the top of the fez. If necessary, you may make a few small cuts around the edge of the top of the fez to avoid gaps in the felt.
Eighth, turn the fez right-side out and shape the fez to your liking. Sew the tassel on top of the fez. Add any additional embroidery or other decoration that you desire.