I got the inspiration from the vinyl rain coats . when i searched for rain hats, i didn't find any in the shape of the sports cap so i think it's a new creation (or at least i think it is :) )

it suits people with short hair more than long hair, but you can wear it with your rain hoodie to cover the back of your neck

enjoy!

Step 1: Get Your Measurements and Make Your Pattern

you have two options

first one, is to scrap an old fitted cap and use it's pattern as a guide

second is to draw the pattern from scratch.

the first one is easier, but if it is not available , try your custom made pattern on a scrap of fabric before cutting the actual fabric to make any necessary alterations.

Taking your measurements:

using a human head or a mannequin head , measure: 1- the circumference of your head passing by the middle of your head and the lower back of your head as shown in picture (line x)

2- measure the circumference of the top of your head (before the slope inclines ) (line y)

3- measure the distance between X and Y.

4- measure the distance between the center of your head and line Y .

Then, to draw the pattern : i divided both circumferences by 5 (as i decided to make the cap with 5 panels)

i draw the panel as shown in picture 2 join the edge with a smooth curve .

to make the other part of the cap , i used the circumference to know the radius of the head( using the 2πr rule ) .

i drew a circle using this radius and i drew the flip about 6 cm away from the circle as shown in picture 3 .

p.s: make sure you add your seam allowance in each pattern.

Step 2: Cutting the Patterns

i used printing paper to draw the patterns and the transparent vinyl medium weight as my fabric .

i traced all patterns using permanent ink fine pin because any other pen would be erased and smudged easily . and cut the flap in two layers ( as one layer won't be stiff enough)

p.s.: the pattern in picture 2 is elongated ( i did my alterations lately so it's shorter and fits better)

Step 3: Ironing the Vinyl

the vinyl might come flat and nice or have some wrinkles

to get rid of the wrinkles : i used my iron on medium heat , put the vinyl pieces and covered them with a 100% cotton fabric , then i pressed the panels flat.

when you heat the vinyl it becomes thinner and can curl up easier so it's important to put a heavy book on it as soon as you remove your iron to press it until it returns to it's normal temperature .

for the flap part i put the two layers on each other and ironed them together , so they stuck to each other. since they were stuck but not entirely they created air bubbles between them , which i liked and decided to leave

Step 4: Attach the Panels

i used a number 3.5 stitch in order not to tear up the vinyl with smaller stitches

first, i joined the first two panels together ( right sides facing) then i flipped it in to the other side (right side facing you) and did an over stitch on one side (instead of opening the seam i gathered both seams in one side to prevent water from penetrating through the exposed seam ) and i used a stitch no 4 for this.

i joined three panels together and then i added my patch ( you can add any embellishment you want in that step before you close the panels together and it gets harder to sew.

then , i joined the other two panels together to add the back opening.

Step 5: Making the Back Openning

i drew the curve on both panels and cut it before stitching them together

then, you stitch them and do your over-stitching.

in order not to leave the vinyl sharp and also undefined , i added bias tape ( will be explained in details the next step)

Step 6: Adding Bias Tape

since the vinyl don't fray , you don't need to hem it or do overlook stitching . But, its edge can be sharp , and its transparency need to be defined ( design wise) .

so, i used some light black fake leather as my bias tape ( i cut it 2.5 cm wide in different lengths , and in the warp direction)

to add the bias tape

step 1: stitch the tape to the edge of the main fabric (wrong side of the fabric facing the right side of the bias in the way shown in the 4th picture

step 2: you flip the fabric and the bias tape , bend the tape inwards and make your second line of stitching as shown.

Step 7: Assembling Everything Together

you now have:

1- three panels attached together

2- 2 panel attached together

3- the flap (we have already added its bias tape to it )

what we do it :

1- attach all the panels together ( and don;t forget to make your over stitching, it gets harder ass you add panels but it's manageable)

2- attach the flap to the cap ( the center of your flap should be attached with the center of your center panel ( it's better to choose odd number of panels to always have a central panel)

3- add the bias tape to the bottom edge of you cap.

Step 8: Adding the Back Snaps

instead of adding scotch tape , i added a snaps tape

i cut a long vinyl rectangle ( 2.5 wide)

i folded it in half , stitched it all around and attached it to one panel , i then added the tape , measured the place of the other tape , and stitched the other in the body of the other panel

Step 9: Making Your Embelishments

here i used the batman logo , but the technique can be used with any other things

the fun in vinyl that you can use any permanent pens to draw on it any shape you like

here i cut out the logo in both the black fake leather and the vinyl , and since the leather has a somehow sticky surface i ironed both layers together , so it became one layer ( if you are using fabric you would need to stitch it with the vinyl ( the vinyl layer is a must if you are wearing the cap under the rain.

i then carefully stitched the logo using stitch no 2.5 on , 1 mm away from the surface of the patch