Hello to all Millinery enthusiasts 

I do not have a smaller mad hatter block version and I have been trying with buckram but cannot curve the sides as wanted. So I started the rather insane frame from scratch in wire.

I have my nice defined sides curved, the proportions sound right. It fits my head. I can play with slight asymmetry because it is flexible but it is still not sturdy and I have gaps. It is about 6.5 high. I need to cover the gaps and make it stronger. What can I do?
 Yes I suppose batting? Or? 
How do I make my frame stronger?

it took sew long already. 

thank you