Introduction: How to Make Patrol Cap

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Step by step instructions with video tutorial incase you get stuck.

Step 1: Video Instructions

Checkout the video if you get stuck on a step.

Step 2: Supplies List

Here is a list of supplies and links to help you with the project!


Link to Buy Beginner Cap Kits:

Patrol Cap PATTERN -

Link to buy 4423 sewing machine off Amazon:

LINK to Buy Polyester/Cotton Twill(recommended for hat construction) Fabric By The Yard Here:

LINK to Buy Bias tape folder attachment:

Step 3: Trace and Cut Pattern

-Print the pattern off. Tape the pattern together.

-You will end up with

1 top panel, 1 middle side panel, 1 bottom side panel

-Fold the top panel in half on line and place on fold of fabric. Folding the pattern in half and placing it on the fold will allow for a more symmetrical circle. Trace and cut ONE.

-Place bottom and middle side panel on the bias of the fabric. Trace and cut. The bias is always diagonal to the weave of the fabric. You will need ONE bottom side panel and TWO middle side panels.

Step 4: Sew Middle Panels

-Take the middle panels place right sides together and sew the front and back.

-Trim the fabric close to the seam. This will set out for adding the bias tape.

Step 5: Setting Up Bias Tape

-Place the twin needle into the domestic machine.

-Switch machine to zigzag stitch with 0 width.

-Add folder on to the machine. We used tape because our folder is designed for a industrial sewing machine.

-We show two different folders. They both make the same fold and will have to be taped onto a domestic machine. The yellow one is linked in the list of supplies and the industrial one is available at

-Thread the machine with two spools of thread and you are good to go! Thread both spools on the same exact path.

-You totally can just top stitch this seam like normal if you want. We use the bias tape for a more professional finish.

Step 6: Adding Bias Tape

-Trim the access fabric from seam.

-Cut bias tape to the size of folder.

-Place bias tape in the folder and start stitching.

-Be sure to stay in the center of the seam. This will add a nice top stitch on each side of the seam. Giving your patrol cap a professional look.

Step 7: Attaching ​Top Panel

-Mark the middle of the top panel. This is easily done by folding the top panel in half.

-Line the center up with the front seam of the middle section that was sewn in the previous step.

-Start at the center seam and sew around the top in a full circle.

-Do not pull the fabric. Let the fabric fall into place. This helps with sewing curves on any project.

Step 8: Bias Tape Top Panel

-Do the same for the top seam.

-Place the folder on the machine. Cut the tape. Start sewing on the center of the seam.

-Make sure you stay in the center and go slow. This step can be tricky with the curve. Practice makes perfect!

-Make sure to cut the bias tape long enough to make it all the way around the cap.

-When you approach the end. Sew over were you started so you cover the beginning of the bias tape. Back stitch to secure the tape.

Step 9: Adding Bottom Panel

-Place the bottom panel on the middle panel with right sides together.

-Sew all the way around bottom of the crown attaching the bottom.

-Remember not to pull the fabric while you are sewing. Work it around for best results.

Step 10: Making Bias Tape

-Using the bias tape kit. Pick the side you would like to use.

-Cut the fabric for the size folder.

-Feed the fabric through the folder and begin to pull the folder with iron trailing.

-You will end up with a double fold tape ready to cover up the back arch opening.

Step 11: Attaching the Bias Tape

-Take the crown and the bias tape.

-The bias tape kit comes with a presser foot guide. You can use this to help attach the bias tape onto the raw edge.

-We attached it without the presser foot. Fold the tape in half and place it over the raw edge. Go slow and be sure you are sewing all layers.

Step 12: Adding Size Strip

-Take the size strip and sew it on the inside of the crown along the bottom.

-Sew directly in the center of the size strip.

Step 13: Making Brim Sleeve

-Place the brim you are using onto the fabric.

-Trace the front curve.

-Stitch directly on the trace.

-Cut about .25 inches from the seam.

-Flip sleeve right side out and insert the brim.

Step 14: Locking Brim Into Sleeve

-Use zipper or narrow presser foot to sew along the back edge of the brim.

-This will lock the brim into position and tighten the fabric.

Step 15:

-When the brim is sew into the sleeve.

-Stitch on top of the brim near the outside edge. This will secure the fabric even more onto the brim.

-We are using a brim guide. This guide is build for a industrial sewing machine so we had to lock it down with tape. The guide helps with getting parallel stitches around the brim.

-Cut back access fabric about .5 inches from the brim.

Step 16: Attaching Brim to Crown

-Make front center of top crown and back center of brim.

-Place right sides together and sew from the center towards the outside edges. Repeat for the other half of brim.

-This will help keep the brim in the center of the crown.

Step 17: Attaching Sweatband

-We made a guide out of heavy stock paper. Make sure it fits the sweatband nice and snug. This will keep the sweatband from moving around while sewing.

-Tape the guide on the machine.

-Roll the edge of the crown over so the wrong side of the sweatband is touching the right side of the crown. Begin to sew.

-Use a zipper/narrow presser foot and start sewing around the bottom attaching the sweatband. Keep as close to the edge of the sweatband as possible.

-This process will attach the sweatband and also provide a top stitch.

-You can also make your own sweatbands by folding fabric in half or you can buy premade professional ones at

Step 18: Adding Back Closure

-Take your desired closure. offers a wide variety of closures to take your cap to the next level.

-Fold the sweatband into the cap. Sandwich the strap between the sweatband and crown.

-Stitch into place and repeat this process for the other half.

Step 19: Adding Vents

-We are using eyelets for vents.

-Mark and cut two holes on side of middle panel.

-Place the eyelets in the holes and use grommet press to secure the eyelets into position.

Step 20: Cap Is Complete​!

Thank you so much for reading our instructable! If you get stuck be sure to peek at the video for help! We will be adding more instructables in the future!

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