So.. I've decided to try and make my own. I'm starting out with craft foam, since the stiffened felt I have doesn't curve well. It just wants to bent and kink at odd angles. I thought about soaking it in water and keeping the felt's shape with somthing like elmer's glue, but to do that, I'd really need a base. I'd have to have somthing made out of wood or plaster, etc shaped exactly how I want the had to look so that I could take the water/glue soaked felt peices and let them dry on that form. Looking at Millenry supply websites, this seems similar to how they form felt hats.
ANYWAY.. craft foam& super glue seems to be working ok for the base. I can't get the exact curve in the body of the hat that's shown in the photo.. but I hope it'll be good enough. It'll definitely be better if I can get the brim to curve correctly.. but so far I haven't figured out how in the world I am going to get that to happen. Maybe if I super-glue some floral wire to the outside of the brim of the hat (when I cut it) I can get it to keep a shape that way.. and when I cover it in fabric, no one will see! XD Oh well. Got lots of costume stuff to work on -..-