They are supposed to be made out of 'unique' fabrics, because welders are very proud of their welding caps!
Taco, Vet2Be's good friend, is a welder, too. His mom, Sheepy, made him a cap and tried to use the pattern I used, but it was very difficult to follow. This tutorial is for her!
Ricochet and Away has a post about a welder's hat. The pattern I used can be found here. The instructions are found here.
All the photos in the following tutorial are mine. I did make two small adjustments so the cap would fit Vet2Be's head better. I'll note them in the tutorial.
You'll need either 1/2 yard of fabric OR two 1/4 yard pieces to make a reversible cap. I used some of Vet2Be's favorites.
You'll also need thread (duh!) and a small piece of flannel or thin batting for the bill. I used flannel because it provides a little bit of weight without too much bulk.
Print the pattern out so that the pattern is the correct size. You can either use your printer's scale function or you can re-size the pattern in a drawing program.
|Fabric A: (Clockwise from left) cut one strip for the band that is the same as the head measurement plus 1/2" x 1 1/2" wide. The pattern says 2" wide, but 1 1/2" fit Vet2Be's head much better. Cut four Front/Back pieces, one bill, two Side pieces.|
|Fabric B: (Clockwise from left) cut one strip for the band that is the same as the head measurement plus 1/2" x 1 1/2" wide. Cut four Front/Back pieces. One bill from Fabric B and one bill from flannel or thin batting. Two Side pieces.|
|Place the bill pieces right sides together with the flannel on the top. Sew around the longer curved edge using a 1/4" seam.|
|Trim the flannel (or thin batting) close to the seam allowance to reduce bulk.|
|Turn right side out, press. Trim the raw edges of the bill so that they are even.|
|Pin around the edge of the bill as shown to keep the fabric from shifting while you are top stitching.|
|Top stitch close to the finished edge, then add as many top stitching lines as you like. Mine are about 1" apart.|
|Stitch Fabric A side pieces together, right sides together, along the top (short) seam. Repeat for Fabric B. Press the seam open|
|Stitch a pair of Fabric A Front/Back sections, right sides together, from the bottom to the dot. Back stitch at the dot. Repeat with the other pair of Fabric A Front/Back sections and both Fabric B Front/Back sections.|
|Press the seams open. I shouldn't have placed my pieces so close together! The photo really shows four different sections if you look closely.|
|Place the Fabric A and Fabric B Side pieces wrong sides together and pin or secure so they don't shift while sewing.|
|Stitch the other side seam in the same manner.|
|Pull the Side section out from the Front/Back section and the seams should all be hidden. Press to set the seams.|
|Repeat Step 3 with the other two Front/Back sections.|
|Sew the short ends of Fabric A band, and Fabric B band. Press open.|
|Fabric B on the outside.|
|Fabric A on the outside.|
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