Forgot to say, it has to look "period", but also cover his head to meet health code...

The ones I've seen are basically just a bag with a band. Here's a site I found. I think that a person could rig something up pretty easily without a pattern since the only part that really needs to fit is the band.

Annie

Here is a link that might be useful: Ren-faire berets

Thankyou Annie!

Hi there,

I have made these before and they are easy peasy.
For the hat band, cut a piece of your fabric 4" in width by 21 1/2" in length. Fold this in half lengthwise. Once sewn to the hat itself, it will be approx 1 1/2" finished in width.

For the headcovering, (this will sound silly) measure "dinner plate + 2 1/2" for the diameter. So what I did was traced a dinner plate on a piece of paper and added 2 1/2" all around.

Sew the ends of your band together to form a circle and then you will need to pleat the headcovering to fit the band as you sew.

Hope that makes sense...