Here are some pictures of how I do the inner wiring for my beautiful green bird. I have used a large brim block as a base to shape the wire. With the pattern drawn on a piece of paper I have traced a line where I want the wire to go, and that done I have placed the paper on top of the brim block and pushed small pins all along the lines where the wire is supposed to go. The bits where the wire has to bend have many pins, while there are no pins where there are straight lines. After doing that I have been able to easily measure how much wire I was going to need and cut it to size before starting. With needle nose pliers you can make little circles on the ends to avoid snags and make it easier to sew in place. I’ve sewn the wire in place by hand without getting to the other side of the felt.
I want to thank Montez for giving me the idea for the rig I’ve made to shape the wire. Check it out for yourselves, here’s where my inspiration came from: http://chapeaudujour.blogspot.com/2008/11/quills-and-spills.html
I hope you will be able to use this technique to make your hats. Needless to say this bird is my design, so please do not copy it… I’m sure you can think of something else that is as beautiful!