We started our pirate unit today! I always have mixed feelings about this theme. The kids love it, and of course it's exciting, but the kids can get pretty rough with their play. But it's only for a week, so I can handle it. For our pirate hats, I used large construction paper. To make a template, I folded one piece in half and drew half of a hat. Then I cut it out and opened it up. Each child got two hats stapled together on the ends.