How to Make a Tony Tony Chopper Cosplay Hat - Free Top Hat Template / stl Antlers One Piece Cosplay
by SKS Props
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What this video covers
This tutorial walks through building the iconic top hat worn by Tony Tony Chopper in the Netflix live-action One Piece series, using EVA foam as the primary structural material and fur fabric for surface coverage. The creator provides free downloadable PDF foam templates and free STL files for the 3D-printed antlers, making the project highly accessible. The construction method is general enough that viewers can adapt it to create any custom top hat design. At under ten minutes, the video is concise and beginner-friendly.
Key takeaways
- ◆Free PDF foam templates and free antler STL files are available on the creator's website and MyMiniFactory
- ◆The hat base is built from EVA foam, then wrapped in fur fabric to match the Netflix show's look
- ◆3D-printed antlers are added as a finishing detail for screen accuracy
- ◆The same top-hat patterning method can be customized for steampunk or other cosplay styles
- ◆PDF templates should be printed using Adobe Acrobat's 'Poster' setting for correct scaling
Who this is for
Cosplayers and prop makers of any skill level who want to build a screen-accurate Tony Tony Chopper hat — or any foam top hat — for conventions or Halloween costumes.
Tools mentioned
- • heat gun
- • hot glue gun
- • utility knife
- • hobby knife
- • leather punch set
- • wood burner / hot knife
- • Dremel
- • Dremel flex shaft
- • cutting mat
- • mechanical pencil
Materials mentioned
- • EVA foam (HD-Foam)
- • fur fabric
- • foam clay
- • Flexbond
- • Plasti-Dip
- • contact cement
- • super glue
- • wood dowels
- • PVC board
- • acrylic paints
- • graphite powder
⚠ Safety notes
Use heat gun and hot knife in a well-ventilated area and keep them away from flammable materials; exercise caution with sharp utility and hobby knives.
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