Picture of How to make a Cadet-style cap
It's been my experience that finding a good fitting Cadet style hat is difficult and even if you can find one that fits correctly, I've found that there is usually some other problem either with the quality of the manufacturing or something else won't be quite right (crooked bill, uneven tops, etc.) This lead me to create my own, and since it's winter time here I made it out of fleece.
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Step 1: Layout of the main part of the cap

Picture of layout of the main part of the cap
first you need to lay out the fabric and mark it for cutting. Because I created a hat with a special logo on the front my cutting is a bit more complicated, but the basics are as follows:

1. Measure around your head where you want the cap's bottom to be. Write this down somewhere you can get to it later because if you ever want to make more hats you'll appreciate not having to remeasure. For my hats I normally create one strip of fabric 23" long by 5.5" tall (I wear a size Small-Medium hat normally).
2. Using a ruler and a marker or pencil mark your cutting lines on the fabric
3. Cut out the strip(s) of fabric (in my case I made 3 pieces: two 10"x5.5" and one 4"x5.5" but normally I would only make one 23"x5.5" strip)

Step 2: Sew the top band together

Picture of sew the top band together
Sew the fabric band together making sure to leave the good side of the fleece / fabric facing out (so basically you'll sew with the fabric laid inside-out).

If you're following what I did and using three pieces of fabric you'll get what's in the photos below, otherwise you'll have only one stitched area that will be the back of your hat.

Step 3: Finish the bottom edge of the hat

Picture of finish the bottom edge of the hat
at this point it's easiest to finish the bottom edge of the hat and give it a nice looking / professional edge.

I fold and pin approximately 1" of the bottom of the band of fabric and then sew it twice; once around the upper part of the fold and once around the lower part of the fold. This gives a nice double stitch that looks good.
JoRowl1231 year ago
I'm in the army cadet force but in Wales! Much more disciplined then the American cadets.
KDS4444 JoRowl1239 months ago

I survived Rookdom in the Norwich University Corps of Cadets. Norwich is located in Vermont. Wales has never seen snow like Vermont. Wimps! :-)

amburjama1 year ago
Great hat! I make hats but never thought of using fleece for a more structured hat. My daughter will love this. I'll make her one in camo fleece this weekend. Thank you!
cwix094 years ago
What is that cutting tool called?
bicarbon8 (author)  cwix094 years ago
it is just a rotary cutter... these can be picked up at any arts and crafts store and are great for cutting fabrics like fleece
If you buy a rotary cutter you may also want to invest in the proper cutting mat, like the author uses in the photos. It looks like a Fiskars brand mat. Olfa is another brand. They are most often found with quilting supplies. Using the mat will GREATLY prolong the life of your cutting blade as well as protect your table, Quite often you can buy a small rotary cutter with a mat in a "travel quilting kit" for a reduced price. If you plan on learning to sew and doing a lot of sewing buy the largest mat you can easily afford. I started with a small mat and immediately regretted not getting the larger one.

If you live in the USA and live near a Joann's or Michael's 40% off coupons are commonly available.
cwix09 cwix094 years ago
and did you use cardstock for the brim or something? and was it pretty sturdy?
bicarbon8 (author)  cwix094 years ago
yes, it was just cardstock... I wanted a pretty lightweight and flexible brim... if I were to make this hat again I would probably purchase a plastic brim insert from a craft supply store and just cut it down to size.
I have used iron-fusible stiff interfacing, like Pellon Peltex 72F for hat brims. You can buy it at fabric stores like Joann's or Hancock's. It's great because it's washable. I also know some people use milk jug plastic for brims.
NOODLE!3 years ago
can this be adapted for duct tape?
Really great job - I'm going to try this. Would it be possible to see a photo of the whole hat inside out? And maybe a close-up of the stitching. I need all the help I can get, thanks, g_g
bicarbon8 (author)  glorious_goddess5 years ago
thanks for the comment, unfortunately I gave this hat away to my bandmate and so I can't take any more close-up photos. The stitching is all pretty basic straight stitch (no zigzagging) and the spacing really depends on the material you use (fleece needed about a 1/16th inch spacing I think). Hope this helps!
OOOOHHH! I will try it
chinchymork6 years ago
wow! looks really nice. great job!!
duck-lemon6 years ago
That's some great work man, keep it up. -Duck