I have read some people make their Mickey Mouse hats with 1/2 ball pan and others with RKT. If you use RKT, do you make the hat hollow (just the shell RKT) or is it a heavy hat....1 big chunk of RKT to fill the pan? I hope this makes sense.

Also, what do you cover the RKT with frosting or melted chocolate before you cover with fondant.

SO MANY QUESTIONS!

i would keep it solid and not hollow. i usually cover in melted chocolate before fondant

I did one using RKT, covered it in melted chocolate then fondant. It wasn't very heavy but it was only about 4" diameter so not sure if that is smaller than you will be using. I would have used the 1/2 ball pan on mine but I don't own one and didn't want to buy one just for that project. I just found something in my kitchen that had that same general shape and used that for the general shape.

If you look at my pics, I did one any use half of a styoform ball. Glued the bottom to a round cake board then covered in fondant. It was light and the customer did want it as cake so it saved me money. Used the Michaels 50% off coupon.

I just made one this weekend as well, I don't have a ball pan so I used RKT's and molded them by hand. I used a 4" cardboard round as the base and built up from there. Iced with buttercream and covered in black fondant. Was a lot simpler than I thought it would be

Thank you everybody for the responses. This answers so many questions. Now do I do styrofoam, RKT or cake LOL