After staring at the mostly-finished coif for a couple of days trying to figure out how to attach the horns, I decided to try to use a large button inserted into the smaller hole. I knotted it on a long length of hemp cord — about a yard, because I didn’t know what else I was going to do with it, and wanted to be sure I had plenty — and pushed it into place, where it seemed to hold fairly well.
I marked the placement of the top of the horn with a pin, so I knew where to attach it. Using the tapestry needle threaded wi the hemp cord, I tried to get the needle through cloth layers and Peltex (four total layers of fabric, plus the stabilizer) and simply could not push the needle through it. I had to use an awl to make a hole just to get the needle through, and then had to pin the fabric layers together because the outer fabric and the lining didn’t want to match up when I did.
Satisfied with the placement, I knotted the cords, but didn’t cut them (just in case). If you use a pin or even a pencil in the center/base of your knot as you pull it tight, you’ll get a nice, tight knot that hasn’t wandered from where you wanted it. Even with that trick, I wasn’t able to get the horns as snug to the sides as I wanted them to be, as they needed to be to look right.
NOTE: Don’t do what I did! Do the finish work on the coif before you attach the horns! It was a pain in the butt to work around the horns — don’t do that!
I used perle cotton (for embroidery) for the whipstitching detail on the seams. I had some waxed cotton that would have looked fantastic, but when I tried to pull it through a scrap of the ultrasuede, the fabric tore a little, and I didn’t think I could get it through that and the broadcloth lining without seriously straining the material. The heavy tapestry needle and the thick embroidery cotton were bad enough, and pretty hard on my fingers — this is a good time for a thimble, if you have one.
I made the ties with broadcloth, not wanting to “waste” the expensive ultrasuede on something that wasn’t really going to show. Those are finished, no fraying; I stitched them, turned and pressed them, and tucked in the ends and stitched them down, too. When I sewed them onto the ends of the coif, I double-stitched them. I sewed down the width of the tie, moved the fabric over about an eighth of an inch (with the needle up) and then sewed the same line in reverse. I’m pretty confident the ties are secure. I tried to brighten the photo to show the detail, but it’s black on black, so it’s still hard to see.
As I was doing on the finish work (that I should have done before I started on the horns), I thought about how I was going to get them snug to the side of the head. Sewing them wasn’t an option; thread would tear right through the foam, and getting a needle through the Peltex and the foam would require a really wicked curved needle, assuming I could get it to work at all. The foam at the bottom of the horn, the flat(ish) part, is actually pretty thick. What I came up with that seemed to work is ridiculously simple: diaper pins. They can be tricky to find, but I have bought them at fabric stores, and every costumer should have at least a dozen of them at all times. Srsly — they are incredibly useful. Every bellydancer I know swears by them. (DO NOT USE SAFETY PINS! Safety pins can pop open and will gouge you, or whoever you made the costume for, in the head and make you very sorry.)
Because they’re so lightweight, the pins hold them tight to the fabric; because the Peltex is so sturdy, it doesn’t flex much or give the foam horns much opportunity to move and tear. The pins are high enough up on the coif, practically in the seams, that they aren’t uncomfortable (so sayeth my model, who could tell something was there, but not what). Would I want him to wear this out in a hurricane, or heavy rains? No, but I think it will hold up to reasonable wear, and I’m really happy with how it looks.
All that’s left now are the accessories, and then I can get started on my own cosplay. (W00T!)