There were a few left over pieces of chino, after I made a grocery tote out of Ning's old trousers. As posted before, I like wearing cadet caps. Without that protection, I bump my head regularly, leaving divets and scabs on my scalp, which I don't like. I use an old, disassembled cadet cap for the pattern. However, I add 1/4 inch to each dinension for better fit. Chino fabric is perfect weight and comfort. This time, I used scraps of flannel for a lining, quilted the top part for scalp padding, and made it reversable.
Laying out the remaining trouser parts and patterns. Will it work? Note, I didn't wind up making the unnecessary hat band.
This time, I added more stiffness to the brim, using medium weight fusable woven interfacing in addition to the thick foamy interfacing I usually use. For the lining, I used exactly the same pattern as the shell. It will shrink just a little, I think. The sides are stiffened a little too with a medium weight, nonwoven fusable interfacing.
Then the hat is sewn together inside out, with a big gap at the back. I had to hand baste the brim, which points inward at this point. It's too difficult to pin or clamp the stiff, awkward, thick three-part sections, but hand basting actually works.
Then turn right side out and sew the rest together. I hand basted that together too.
The cap came out pretty decent. I think it's the best made of my attempts, so far. The chino fabric, with interfacing, is the perfect stiffness / warmth / comfort. The added interfacing makes the brim stiff enough to hold its shape, without being a herd piece of plastic. I like it better without the hat band. This brim came out better too. I used an edge hem to hold its shape, and drew the lines on the fabric before sewing, using a washable fabric pen. That helped a lot.
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