First , I took Lord Zonkers basic pattern,http://brassgoggles.co.uk/forum/index.php/topic,31765.0.html
tweaked it and modified it.
Then I took akumabito’s Baseball cap Ideahttp://brassgoggles.co.uk/forum/index.php/topic,29435.0.html
and tweaked and modified that for the visor…
basically I didn’t come up with anything original, hmmm, I’m just like Edison
Oh I’m the very model of a modern major Edison
I’m going to steal it all so shut up and take your medicine….
( gimmee a break folks, I’m working on the fly here)
You’ll need material, an Old baseball cap and the plastic lid to a 2lb coffee can
Step 1), You need your patterns You can use any material you want but heavier material like wool, muslin, etc. seems to work better.
First, Cut a Circle pattern out of paper, manilla envelope, oak tag ,etc, 5 ½ Inches in dia.
2) On your material, mark out TWO of these circles
3) Cut the circles out
4) Take your plastic coffee can lid
5) And trim that down to about a 5” Diameter circle
6) Place the plastic disc between the two cloth circles and sew it all together along the outside edge.
7) Now you’ll need a patter for the main part of the hat. I wear a 7 3/8 size hat so you can adjust as needed. ( Also refer to L.Zonkers site if necessary)
The dimensions are
11” on the top, 3 ½” on the front side, 13” on the bottom, 5 ½ on the rear side. This is half of the pattern.
Lay the pattern on your material and mark the material.
9) Flip the pattern and repeat the process
10) Cut the material out, leave yourself about ½” extra so you can fold it to the inside and have decent looking edges.
11) now fold the edges over and sew them so everything is nice and neat and squared away.
12) If you’re going to want a colored band for branch of service, add this at the bottom now. (IE: Blue for Infantry, Red for Artillery, something like I did just cause it looks cool.)
13) Now you’re ready to sew the top to the main part. Start at the front ( where the 3 ½ inch wide ) part of the hat is. When you get all of the way around to the back, do not sew it completely up, leave the back seam open.
14) If you want, put a couple of pins in the back seam to hold it together so you can see if it’s what you want.
Warning cute, innocent baseball caps
were butchered in the process of making these. If the baseball cap rights people don’t like it, they and Abner Doubleday can go somewhere and cry.
15) Cut the plastic visor out of the cap
16) Now you need a pattern to cut your visor to proper shape. Mine is 5 ½” long by 3 ½” wide
17) Now you sew what is more or less a “bag” of material that your visor will fit into
18) Now turn the bag “inside out” put the plastic visor in and sew as tightly to the visor as possible
A quick note. Real US CivWar and French kepis and Forage caps of the time had leather visors, not plastic and cloth, as well as a leather strap around the front half of the colored band in, case you want to go all out for authenticity. However this is NOT re enacting. If it were, and you made one of these, the Stitch Nazis would come and throw you in Re-Enactorshwitz where you would languish until a bunch of out of shape, overweight middle aged guys wearing WWII American 101st airborne uniforms came and liberated you.
19) Sew Visor to Kepi
20) Sew up the back seam
It should look like this
I’m sure with the talent on brass goggles, you people should be able to produce even better stuff if you want.
I think next, I may try a French Foreign Legion stovepipe version.
( OMG do I need a shave!!!!!!)