I wanted to show how to make a cap but could not find a pattern so I took apart my very old cap that I use to protect my hair when I garden. There were only two pattern pieces I had to cut out of parchment paper. One for the cap panels and one for the visor.
Step 1: Basic Supplies Needed
You will need the following supplies:
Pins, needle & thread. A sewing machine makes most of the stiching easier, but one is not necessary.
Parchment Paper. Ruler & pen or pencil.
Old pair of jeans or any fabric. Lightweight fabric for lining.
Any kind of stencils, stamps, transfers or fabric markers if you care to jazz up the cap.
Small piece of heavy interfacing for the visor.
Some kind of elastic to add to the hat in the back as needed.
Grosgrain ribbon for the inside cap band. Velcro is optional.
Step 2: Making the Patterns
Unless you are using a hat you already have and wish to try the same thing as I did, you will want to use the shapes and dimensions that I show for the visor and the panels.
First you will need to cut the patterns from the parchment paper using the dimensions in the pictures.
You will need to cut two of the visors from your fabric as well as the interfacing for inside added visor stability. 8 1/2" x 4" making sure that you try to keep the curve as specified on the image.
You will be cutting 8 panels each from the cap fabric and the liner fabric. Again using the diagram, the length of the panel is 9 1/4" x 6", 3 1/2" from the bottom center. The top of each panel is only 1" across. Be sure to make the curve on the bottom ends, which will make it slightly longer on either side, but only by about another 1/4".
Try to see if you can size these pattern images for your printer so you can just print the patterns out ready to use.
Third image was to show that I cut about 1/4" out from the edge of the pattern so I did not cut into it and it also made the hat a little larger than my original. This pattern should fit a large head so if for any reason you are much tinier, you can adjust it after sewing by making the seams a little wider then the usual 5/8".
Step 3: Pattern Issues
You may find that thinner paper curls but you will be pinning this anyway. You can use parchment, printer paper, freezer paper and even stiff interfacing for a pattern that won't tear on you.
I also made sure to cut 2 panel patterns because of the need to cut 8 pieces each of the cap fabric and the lining.
If you wish to make a cap like mine, you will be using an old pair of worn jeans. My fabric was a bit heavy so some of my last sewing I did by hand due to all the layers of fabric that needed to be sewn through.
This is another reason I cut 2 patterns for the panels. Since I was using an old pair of jeans, the legs are the perfect size to pin your panel patterns to. After cutting the first set from the bottom of each leg, you simply move the patterns up the leg and cut out the next set and you have all 8 panels.
Then just place the visor pattern anywhere above that on the jeans, there should be plenty of fabric left. Just be sure that there is not a hole or a pocket or anything odd on the back fabric before you cut the panels out.
I have even made jean cuff braclets with the boot cut jean styles by cutting off just a couple inches off the bottom hem of each leg first, stitching them together and putting on whatever embellishments I wanted (see additional picture). That's another instructable.
Step 4: Decorating Garden Cap
If you wish to add any embellishment to the jean panels, you want to do it before you sew the panels together and especially before inserting the lining to the cap.
I used stencils, fabric markers by Crayola, transfer paper with flowers and even inkprinted dryer sheets, but that's another instructable.
I added some metallic stitching over some of the stencils and free motion over some of the transfers. You can use the letter stencils to spell whatever you wish. I choose to write Peace, Love, Hope & Garden.
Step 5: Sewing the Panels
Sew the panels together starting on one side of the 4 pairs of the lining and the cap fabric. You can see that my pins are all on the left. I try to be consistant when I work on my projects so there are less problems. Once these are sewn, keep sewing each panel set together in the desired pattern until all 8 are attached.
The sky is the limit for the fabric types and color. A lined jean hat is very warm. If you are gardening in the heat of the summer, you may want to make a cap in a percale or loose weave cotton of some kind. You may choose not to line it, but you will have to finish your seams and still attach a firm ribbon inside as a band.
There is usually a small opening in the top center of the panels and you will want to sew across the top of each panel set about 1/4" per photo images below.
Once all the panels are sewn together, input the lining to make sure it fits as it should in case you need to make any adjustments before sewing in place.
Step 6: Attaching the Visor
Sew on the interfacing when you stitch the visor rim together.
Be sure to trim the seam as well as snipping little V's out, being careful not to clip the stitching.
This will help the rim to curve nicely when turned right side out.
Pin visor to the front of your cap. When you are sure where you wish to place it, baste it in place so you can take out the pins.
Step 7: Sewing the Liner to the Cap
Place the edge of the lining to the edge of the cap right sides together, seams together as well and hand or machine baste about 1/2" in from the edge starting on one side of the visor, ending on the other side of the visor.
Sew with the 5/8" seam and turn right side out at the area left open above the visor.
Pin the grosgrain ribbon inside with the open or velcro part in the back. Be sure to leave a small area free attaching any elastic either inside the lining before finishing or you can actually stitch with elastic cording in the lining in the back area if you need a tighter fit later.
Step 8: Stitching the Band in Place
Due to the layers of heavier fabrics you will want to hand stitch the grosgrain ribbon in place unless you have a machine that made is for heavy duty sewing. Be sure that you leave part of the ribbon unattached if you have added something that allows you to adjust the size of the band, such as velcro. Again, you can add any elastic as needed to improve looks and the fit in that area.
Cap is ready to wear after you make sure all needles and pins have been removed.