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Here's how we made my headpiece. If I should post this somewhere else let me know :)
(Unfortunately I don't have in-progress pics!)
We started out by coming up with a pattern and drawing it out on cardstock. We taped the cut-out shape onto a coffee can, then applied a bondo/resin milkshake over the top and let that dry in the curved shape. Then reinforced the back with fiberglass.

It was a little fragile (the ends are broken now from me putting stuff on top of it, d'oh - having to make a new one for DC).

To keep it on my head I got one of those cheap plastic headbands and covered in fabric. I glued that to the back of headpiece, then added some extra length so it could be tied tighter.
Here's what the backside looks like:


I put the headpiece on before the wig, tie it tight and secure it with a few bobbie pins, then put the wig on.
Another view:


At the first con I wore it too, I realised the bottom edges were wanting to stick out more than I liked. I had to come up with some quick way to fix it there in the hotel room and ended up sacrificing the hair ribbon from my Belle costume. I glued them to the inside bottom edges, and just tie those around the back of my head too. If I'd noticed the issue before the con I would have at least done something that would have matched my hair! LOL

When we make my new one I'll take some pics of it in-progress and post them up as well