A DIY Sun-Protective Brim for a Bicycle Helmet

INTRO - My girlfriend and I are doing a shakedown cycle tour in prep for our impending two-year bike tour from Vietnam to Mexico [via SE Asia, China, Kazakhstan, Europe, Quebec, and the US] starting in Feb next year.

At the moment we're heading south down the east coast of Australia (from Cairns to Sydney ) and damn the sun is relentless...

Anyway, since I really like my funky new bike helmet but it provides no shade for my face or neck, I've adapted an eleven dollar white canvas cricket hat to the task.

Step 1: Necessities Etc -

What you'll need...

cloth hat
sewing machine / #10 hand sewing needle
pencil / chalk
thread
scissors
scalpel
cutting board
beer...

Step 2: The Process -

The pictures should express most of it really, but here goes -

Find a suitable candidate. White to reflect the sun, canvas to breathe, and CHEAP.

Cut the crown off - to minimise discomfort and maximise ventilation. I cut less off the back to cover the big gap. The front is about 30mm high, and the back is roughly 80mm...

Mark the slots for the chin-strap, and cut out with the scalpel. It's easy to cut more out later, but harder to fix if you remove too much too early... I cut the slots about 4mm wide and 120mm long

Check that it all fits before you finish it...

Bind the edges. With a sewing machine, or by hand, zig-zag or blanket-stitch over the cut edges to keep the fabric from fraying. Reinforce the sliced-through vertical seams by sewing back-and-forth a bit.

Now whack it on ya noggin and get cyclin', safe from the sun.