After a couple of failed attempts, I finally got one that I like, and will actually wear!
The pattern came from a book “Sewn Hats” by Carla
An old torn-out pair of jeans was used for the shell. An old bandana is the liner. I used a flat piece of plastic clamshell packaging to stiffen the brim and some black double-fold bias tape for the band.
Looks decent enough to wear: