How to Make a Cheesehead Out of Styrofoam

The original Cheesehead hat was constructed in 1987 out of two pieces of polyurethane furniture foam. What started out as a comeback for a derogatory remark in the newspaper by some Chicago White Sox fans (“cheesehead” wasn’t always a compliment), became a multimillion dollar business and a necessary fashion accessory for all proud Green Bay Packers fans and Wisconsinites. If you want to show your Cheesehead pride, you can construct this wedge-shaped, cheddar/Swiss cheese hybrid from several Styrofoam blocks.

Things You'll Need

  • 3 2-by-12-by-18-inch Styrofoam blocks
  • Spray adhesive
  • Ruler
  • Permanent marker
  • Saw
  • 220-grit sandpaper
  • Utility knife
  • Spoon
  • Cheddar yellow paint
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Instructions

    • 1

      Spray the top of one block and the bottom of another with spray adhesive.

    • 2

      Press the two blocks together.

    • 3

      Repeat Steps 1 and 2 until all blocks are combined.

    • 4

      Place a 12-inch ruler at the center of the edge of short edge of the block.

    • 5

      Angle the ruler until a 12-inch diagonal connects the center of the edge to the left long edge.

    • 6

      Draw a line along the ruler with a permanent marker.

    • 7

      Repeat Steps 4 through 6 to the left of center. These two lines form the point of the Cheesehead wedge.

    • 8

      Draw a slightly curved line connecting the two lines you just drew. This will form the back of the hat.

    • 9

      Use a saw to cut the Styrofoam along the lines you have just drawn.

    • 10

      Smooth the Styrofoam edges with 220-grit sandpaper.

    • 11

      Lay your favorite had in the center of the cheesehead wedge and trace around it. This will give you a rough circumference for the hat depression.

    • 12

      Carve out the Styrofoam with a utility knife and a spoon until you reach a depth and shape that is comfortable for you.

    • 13

      Carve out 25 small, Swiss cheese-like depressions all over the Cheesehead wedge.

    • 14

      Paint your wedge cheddar yellow.