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.

Step 1: 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)
I'm in the army cadet force but in Wales! Much more disciplined then the American cadets.
<p>I survived Rookdom in the Norwich University Corps of Cadets. Norwich is located in Vermont. Wales has never seen snow like Vermont. Wimps! :-)</p>
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!
What is that cutting tool called?
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 &quot;travel quilting kit&quot; 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. <br> <br>If you live in the USA and live near a Joann's or Michael's 40% off coupons are commonly available.
and did you use cardstock for the brim or something? and was it pretty sturdy?
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.
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
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
wow! looks really nice. great job!!
That's some great work man, keep it up. -Duck

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