NOTE: The foam is glue on in successive lengths to taper down the headband. Use 5 or 6 pieces of foam for a 1"-1 1/2" high headband.
Use a marker or pencil to mark the center of the underside of the headband.
Cut a piece of headliner foam 1 1/2"x 5 1/2" or 6" and mark the center of the foam.
Center the foam on the top of the headband and hot glue it in place.
Trim off the excess foam from the sides.
Cut another piece of foam 1 1/2"x 6 1/2" or 7" and mark the center of the foam.
Center the foam on the top of the headband and hot glue it in place.
Trim off the excess foam.
Repeat the above steps 3 or 4 more times, depending on how high you want your headband. Ending with a piece that covers the headband from end to end.
To make the template for batting and the fabric cover, measure the thickness of the middle of your headband from the inside center mark up and over the top and down (approx 5" or 6"). Then measure from one end over the top to the other end (18"-19").
Draw a paper pattern similar to the one shown using your own measurements. Add 1/4" seam allowance to the pattern.
On the bias, cut out one piece from knit fabric and one piece of cotton batting.
Cover the headband first with the batting. Either sew or hot glue it in place. Trim excess batting as needed.
Fold the knit fabric in half lengthwise and stitch a long gathering stitch along the center 8" or so. Pull tread to gather slightly.
Turn RS out and slide over padded headband.
Adjust gathers to make headband smooth and knot the ends.
Pin the ends in place stretching and smoothing as needed.