Step 1: Pattern
Download the attached ZIP file for the pattern. It contains five files:charlie_brim.gif
charlie_crown.gif
charlie_flap.gif
charlie_side.gif
charlie_strap.gif
I have not worked out a good way to get a paper pattern into a computer. If anyone has a good idea I'd love to hear it. Anyway I traced these in Photoshop... I didn't take the estimated 4 hours I thought it would take to add the seam allowance, so each of these shows only the stitching line. When you print them out, you'll want to cut a quarter inch out from the line; it may be easiest to draw the cutting line on first.
Also: the sizing is probably not correct. I marked a red line with a number of inches on each file, so you may need to make some xerox adjustments to get that marking to the right length.
Thanks for your patience everyone! Please post pictures of yours!