Picture of The Best Cap You Can't Buy
This is a fun headwear sewing project featuring a sleek aerodynamic design, a quick faux-felled seam,  and the most luxurious cuff. In the upright position you get 3 layers of ear protection. Folded down, the cuff will cover your face and neck. Goodbye premature sunrises.

You will need a remnant of 4-way stretch fabric and matching thread. Polyester/spandex blend makes a nice sleepy hat. Brushed rayon blend is cozy for outdoor winter activities. I think this would also work if you were careful to horizontally orient the stretch of a 2-way fleece. But this is South Florida and that's theoretical. 
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Step 1: Cut & Pin

Picture of Cut & Pin
Here we have a 20 x 14 inch piece of fabric folded to 10 x 14 or so. The seam will use an inch and the width will vary with your head size.

A 5 quart bowl was just right for cutting a hemispheric pattern. Then pin the cut edges. 

Step 2: The Faux Felled Seam

Picture of The Faux Felled Seam
I use this method to produce a very strong and stretchy seam in performance fabrics. First I zigzag over the pins with a 3/8 to 1/2 inch seam allowance. Then the pins can come out.

The 2nd row of stitches takes a little more explanation. With the outside still out, I put the free arm inside the cap. Both sides of the seam allowance are folded together flat. Then the 2nd row zigzags across the seam to capture the fabric edges. 

The end of the seam folds to a point and everything is neat.

Step 3: Hemming

Picture of Hemming
The cuff is finished in a similar way. Again, all the sewing must be made with some sort of stretch stitch to accommodate the fabric stretch. Working from the inside out, zigzag stitches capture the edge of the fabric for a minimal hem finish.

Step 4: Done

Picture of Done
Slippery fabric can be challenging. Don't spare the pins. Once you have your seams locked down, it's as easy as it looks here.

Yes they do make great gifts. Cheers from Sarasota.

Step 5: User Guide

Picture of User Guide
wold6301 year ago
I would love to see the cap on someone's head. Do you have a picture?

Nice work - those store bought caps are expensive!
flavrt (author)  wold6301 year ago
As you wish.
wold630 flavrt1 year ago
Hey, thanks! Now you should think about using that as your main image! It's really a great tutorial!