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We covered our whole brims with flannel, as the edges get in this picture.
We picked out fabric to cover our hats with. The best kind isn't too thin or thick, has a small pattern, and isn't shiny. It needs to stretch a little on the bias but not much. I picked a black fabric with tiny silvery white cherries on it (as opposed to the lovely plaid below). We covered both sides of our brim, basting it along the edge.
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For cutting out the hole — we had marked our head-size circle and transferred it dutifully to every layer. We sewed through all the layers along the circle. We did most of our sewing on this hat by hand, which made us feel like authentic milliners. Or have sore fingers, I forget. (Remember that my head is bigger than anyone else's, so sewing my head hole took an extra long time.) You notch the edge so it will lie flat against the crown.
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