Unfortunately, I don't remember the site I consulted for the original hat pattern. Luckily I still had the piece of buckram, so I was able to just trace the shape cut out of it to re-create the curve. This time I cut four layers of buckram, instead of just one, so the hat is hopefully more durable.
I sewed the four layers into a ring, and then sewed a seam along the top and bottom to keep the layers together.
I added seam allowance to the bottom of the crown shape and a couple of inches to the top, and I cut two out of mid-weight white linen. I sewed it together along the bottom, right sides together, and then turned it right side out. Then I wrapped it around the buckram crown, turned the edge under where it overlapped, and sewed it down.
After the picture below was taken, I decided to sew it together along the top edge as well.
I protected the back of the embroidery with pellon interfacing. (Now no one will be able to see if my stitches were neat!) It also will stiffen the top to help the cap keep its shape.
I measured the top of the original cap, added seam allowance, and I drew the oblong shape below. I laid this over the embroidery and cut the shape (which took a lot of courage!). I completely failed to take a photo of this step.
I turned the crown inside out, laid the top across it right sides together, and hand sewed them together. Then I serged the edges on the inside to reinforce the seam.
When I made the original cap, I deliberately put eight spots on it to avoid any question of whether they were considered "pearls" to indicate Court Baronage.
Now that Roana is a Court Baroness, I decided to do six spots, so it can also serve as a coronet. So, I measured the circumference, divided it by six, and marked the place for each spot.
I sewed the teardrops first, by running several loops of thread through the hole in the top and the crown of the cap. Then I attached the top round beads by running a thread through the crown and the hole in the bead, looping it through a black seed bead, and then running it back through the bead and the crown. Finally, I repeated that process for the two other round beads.
And now it's a Cap of Maintenance!