instructables

Sew a Welders Cap

by ckeeling

This instructable is to make a “Welders Cap”. This is a dual purpose hat. You can wear it bill front as a cap or youturn it around and let the bill protect your neck from flying sparks while welding.

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Step 1: What You Will Need:

Outer Cloth - about ¼ yardLining Cloth - about ¼ yardBatting - Scrap (or fusible interfacing)ThreadPattern - There is a good pattern online. I got mine fromhttps://www.flickr.com/photos/sewing_engineer/3226539174/ (EDIT - this previous link I had herestopped working so I have also added an image of the pattern to this instructable. :)).

Step 2: Cut Out Your Pattern

Really Simple - Cut out your pattern. I tend to leave the lines there when cutting out the pattern pieces :).

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Step 3: Cut Out Your Fabric

Following the directions on the pattern pieces cut the appropriate number of each piece out of both fabrics. I DONOT cut the interfacing at this step, but will do that later. This pattern didn't have a piece for the hat band, butremember to measure your head and cut that one too (as per the pattern directions).

Step 4: Transfer the Markings

Transfer the marking from the pattern to your pattern pieces. Use a water soluble pen or chalk pencil so themarkings will wash away.

Step 5: Gather All Your Cloth Pieces

All your pieces should now be cut out and ready to assemble. It's Interfacing Time :).

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Step 6: Interfacing

There are those who cut the interface to match thepiece and then carefully set it on the cloth to apply it, Iam not that exact. I lay my pieces on my ironingboard good side down and then lay a over sizedpiece of interfacing over all the pieces. Once theinterface is set you can simply pull it off your ironing

board and trim the pieces back down to size.

(If you are using a thicker Batting then you will needto sew this to the bill piece(s). Keep your stickingwithin your 1/4" seem allowance)

Step 7: Sew the Tops Only of the Side Piece Together

Lay the two lining side pieces on top of each other, right sides together. Sew a straight line between the two dotsthat you transferred from the pattern pieces (follow what ever seam allowance your pattern states).

Do the same for your outer fabric.

Press the seams open.

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Step 8: Connect Front and Back Pieces

Similar to the sides - lay the two sets of front and back pieces on top of each other and sew one side only of eachset - stopping at the dots. Do this for all 4 sets.

Press the seams open.

Step 9: Complete the Dome

Lay a sewn together section of font/back sections ontop of the connected sides you did earlier. Lay theseright sides together and pin along the edge. Sew theseam from the end to the dot (back-stitch at the dot).

Connect the other open side to the opposite side.This will create a half-bowl shape.

Now connect the remaining front/back section to the

open piece of the bowl.

You should now have a complete bowl shape. This isthe crown of the hat.

Press all seems open.

Repeat all the steps with the outer fabric.

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Step 10: Make the Bill

Lay the two pieces of the bill together, right sides together, pin.

Sew around the larger curved edge at seam allowance.

Clip curve around the larger curved edge. Be careful not to cut the stitches you just sewed.

Step 11: FInish the Bill

Turn the bill inside out to hide the sewn edge. Push the cloth into the seam to get a nice crisp edge. Press theedge and add a line of sewing to the edge to seal it down.

(Some people continue to sew smaller and smaller loops across the bill to give it a more 'finished look'. This mightbe preferred if you're using bating, instead of interfacing, as this will help hold the batting in place)

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Step 12: Connect the Band Pieces

Take the small rectangle 'bands' and join them into a ring at the small ends. Fold the cloth in half length wise, rightsides together and sew across the ends. Press the seams open.

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Step 13: Attache Band to Bill

Line up the un-sewn edge of the bill to one edge ofthe band and pin in place. This can be a little tricky asyour matching a curved edge to a straight edge, butjust take your time and use lots of pins.

Flip the bill over and now match the other band pieceto the other side of the bill. This can easily be done by

removing one pin at a time from the first side and re-pinning it with all layers gathered.

Sew the bill to the band. Don't stop at just the bill, butsew the complete circle matching the two bandpieces, right sides together.

Step 14: Finish the Band

On the outer fabric pull the band up and flatten it so it makes a smooth surface. Pin this seam open and stitch tostop it from bunching later.

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Step 15: Attache the Dome

Pin the outer shell dome to the un-sewn edge of the band, right sided together.

Sew these together.

Press the seam towards the band (press it 'down' into the band).

Step 16: Attach Inner Dome

Turn hat inside out. Put your hand up into thereversed dome and lay the lining dome on top of thecap (and your hand) - wrong sides together. Pull thisdown and tuck inside of the band. Pin.

Once pinned turn hat back right side out and re-pin onthe outside so you can see where you'll be stitching(this is the step that I goofed on and you'll see my

uneven stitch line on the next step).

Remove any pins from the inside of the hat.

Sew along the upper seam of the band. This shouldcatch the inner dome and band keeping it all together.

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Fantastic! I've been using my same old grungy burnt welder's cap for a few years and could reallyuse a new one. Will be making my own from now on :) thanks!

Did you ever make yours? Would LOVE to see how it came out :D.

Where is the band pattern piece? I printed the pattern but it seems to be missing the band. :-(

These are photos of a couple I've made, now instead of lining them I use Pellon Shape flex 101and fuse to each piece and what I do is take a side piece and 1 front, 1 back sew them to eachside, do that with other and then make 1 seam from front to back press all seams open then topstitch with a decortive stitch, sew bill to band press then top stitch it then invert the bowl pin bandon so right sides are together stitch seam allowance all the way around, then I finish with myserger. Turn band down and you can top stitch again.

Does this cap fit everyone? If not how do you take it up if it needs to be smaller?

SWEET!! Although I think construction could be simplified... Will post an alternate assemblymethod soon.

Hello: Do you know if I can get this pattern without paying a membership fee, like a one time fee

Step 17: Check Out Your New Hat

You're DONE! You should have a cute little Welder's Cap. Wear it with Pride and let it do it's job protecting yourneck :).

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Is there a way to get the pattern without paying a membership monthly fee. Like a one time fee

what type of fabric is best for a welder to ware. i want to make my brother one

Use only -ONLY- 100% cotton. And if you put batting in the flap, use only 100% cotton batting.Really, it's fine to just use a middle layer of fabric instad of the batting.

You use only 100% cotton because it won't melt when sparks hit it. Man-made fabrics can melt andburn you.

Made my reversible

how do i get the pattern

I would like to have a pattern. PLease

I hadn't realized the link was no longer good. I have update the link and added an image of thepattern. I hope this helps.

Hubby loved it! Only pattern and tutorial i found where i actually understand whats going on.Thanks to my cricut i was able to adjust the size perfectly. I'm a begginer and i was able to make it.Ended up making 2, once i got the first one done the second was a peice of cake. 3$ for twowelding caps, you cant beat it!

https://youtu.be/ihMCYrEHB8M

Please make a video tutorial

I'm not understanding how to make pattern larger. I made this hat according to pattern printed outand came up with a 21 inch hat instead of a 25.

you have fit to print if you are using a pdf. Uncheck that.

HI there was wondering how i adjust the size of the pattern without changing the shape of thepattern

Thanks

Use the Scale Bar on the side pattern piece.

I made it. Reversible, with name on and entered it in the fair

It looks like you put the side piece in the front or am I looking at this incorrectly?

Works well for my wonderful welder :)

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Hi ,i love your blog !!!!i need the pattern for this caps please

I need to adjust the size of the pattern. I didn't add the band so I will lengthen the pattern tocompensate for no band.

hat 2 of the 4 that i need to make for my cousin!

Crochetamommy I am fixing to try to make some of the welding hats..we are a welding family butmay I ask why the elastic and where did you exactly put it?

i put it about an inch on either side of the brim. i used 2in long piece of elastic, stretching it about3in in total.

I hope this helps!

I have to say, I have made this hat a few times, just winging it and sewing without instructionsbecause I couldn't understand the ones that was out there.. but, I love this instructions!! I havebeen able to make 2 in the time that I made one by myself..

I added a 2in piece of elastic bands to the side of the bill (welder's choice) after I did step 13.

also, In the last step, I sewed the pieces together like i do purses. i put right sides together, sewexcept for 1-1.5in gap, then turn right side out and close the gap.

What a wonderfully laid out and very detailed instruction to make this welder's cap.

Thank you so very much!!! :)

(Will upload pictures of second one when finished with the last step.

I do have one correction based on your photo. The center seam on the two front pieces issupposed to be centered on the bill. I wear them all the time at work being a union insulator andevery hat I've worn has had the seam centered on the bill.

Thanks for your note. It should be a simple update to your hat. Just cut the bill piece in half andadd your seam allowance to the cut side of each piece - sew together and then treat as one piece:).

Again, thanks for your suggestion.

It looks great :D

How do you measure weilding caps in cm. To increase or decrease?

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There are 2.54cm to an inch. You can google a conversion calculator or do the math yourself :D

hi, how do you measure it in centimetres?

There are 2.54 cm per inch. You can google a calculator or do the math yourself :D.

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