First I carved 2 layers of round cake to have a slight taper up the sides. I also carved some small indentations into the sides to give the look of rumpled fabric, like a truly worn hat. That was crumb coated and covered with a very thin layer of white fondant.
The camouflage layer was made by putting “puzzle pieces” of the colored fondant together side by side. First I penciled the camo pattern onto a piece of paper, marked them the color I wanted each to be, and then cut those pieces out. Each piece was used as a template to cut out the corresponding color of fondant.
Each piece of colored fondant was stuck to a thin layer of white fondant underneath with a little water. This under layer of fondant was there to ensure that the pieces stayed together and did not fall apart when I picked up the larger finished piece. I kept the whole piece under plastic while I was working on it to prevent it from drying out.
When I got one piece big enough to cover the top of the hat, I used a slightly fabric textured mat on it to give a little bit more of a fabric look. That piece was then glued to the top of the hat with water. And the excess hanging over the sides of the top of the hat was cut off with an exacto knife.
The same process was followed to make a piece to apply to the sides. I used two pieces to wrap around the sides, and covered the side seems later.
Here is one side piece in place and the top edge trimmed flush with the top of the cake.
The same process was done to cover a cardboard cake circle, which served as the brim of the hat. The cake part was put on top of this cake circle.
And here is the finished product:

































































































































