This is how to build a stylish 'Castro Cap" with iPod Nano pouch.
Step 1: Supplies
An old sweater, preferably sturdy materials ( I used a wool sweater)
A bright or fun colored material or old T-shirt
thick cardboard ( i used the back of my sketch book cover, you can also recycle a yogurt container )
reinforced tape ( duct tape, strapping tape, NOT SCOTCH )
measuring tape or ruler
iPod (this works best for smaller iPods like shuffle or nano, i havent figured out the 2G touch aesthetics ;op )
I started by building the beanie with a brim on Threadbangers
and then modified my patterns to include other styles of hats.
Step 2: Brim board
Trace the brim of another hat onto thick cardboard (not corrugated) or recycle a yogurt container or something that is a sturdy plastic.
Draw the inner edge in a curve.
Cut out cardboard.
Cover with a layer of reinforced tape.
Set aside til step 3.
Step 3: Chop Chop
I use the textured parts of the orginal material to give the hat some flare. In this case I am using the ribbing from the bottom of the shirt and the cuffs of the sleeves.
Start by cutting off the sleeves.
Open the sleeves by cutting off the seam. Stay as close to the seam as possible to get max usage out of the material.
Pin the cuffs together, outsides touching.
Trace the brim pattern and pin around the outside curve.
Sew the two pieces at the curve and trim the excess. It will look like a calzone...
Turn inside out.
Slip the half moon of the brim board into the 'calzone' piece, pull the material tight and pin.
Sew along the pins, keeping the material snug against the board.