How to Make an Engineer's Cap

Make your own engineer's cap.

Whether playing dress up or finishing off a costume, an engineer's cap is a great addition to any child's play clothes collection. An engineer's cap can even be made at home, rather than purchasing one. With blue and white striped fabric you can create a classic cap, or choose your favorite fabric for a more unique look. Whichever style you prefer, an engineer's cap can be made with basic sewing skills and less than a yard of fabric.

Things You'll Need

• 1 yard of medium to heavy-weight fabric
• 1/4 yard interfacing
• Sewing machine
• Thread
• Scissors
• Measuring tape
• Iron
• Fabric-marking pencil

Instructions

1. Measure the circumference of the head of the person the cap is for. Fold your fabric in half with desired display sides facing each other, and lay it out on a flat surface. Mark the circumference measurement on the fabric, adding 3/4 inch for a seam allowance. This is the length of the cap band.

2. Mark the width of the cap band on the fabric as 3 inches. Cut two cap bands.

3. Sew a 3/8-inch seam on the short ends of one cap band. The right sides should be facing each other. Turn the band right-side out. Repeat for the second cap band.

4. Draw a circle on your fabric with a diameter matching the diameter of the sewn cap bands plus 3/4 inch for seam allowance. Cut out two circles. These will be the top of the cap.

5. Sew each cap top to a cap band with the right sides together. Use a 3/8-inch seam. Place caps together with wrong sides facing each other. Turn under the edges of the cap bands by 3/8 inch. Iron the edges and set it aside.

6. Measure the head of the person who will wear the cap, from temple to temple. Mark this measurement on your fabric, adding 3/4-inch seam allowance for the base of the cap brim. Indent the base of the brim by using the cap top as a guide for how far to indent and remark the line. Mark a height of 5 inches above the new base line. Connect the marks by drawing a half circle to form the brim. The brim piece should look like a crescent.

7. Cut out two brim pieces. Cut one brim piece out of interfacing. Layer the pieces by placing the two fabric pieces with right sides together and the interfacing piece on top. Sew the outer edges together with a 3/8-inch seam. Turn it right-side out.

8. Place the brim between the two layers of the cap bands. The brim edge should be inserted 3/8 inch to match the folded seam of the cap bands. Pin the brim in place. Sew around the entire bottom edge of the cap band to complete the cap.

Tips & Warnings

• To add support to the cap brim you can sew a double line around the edge of the brim.

• If you use a heavy-weight fabric for your cap, use a heavy-duty needle (90/14 HJ, or 100/16 HJ) to avoid breaking them.

References

• "Fabric Savvy: The Essential Guide for Every Sewer", Sandra Betzina, 1999
• "Threads Sewing Guide: A Complete Reference Guide from America's Best Loved Sewing Magazine", Threads Magazine, 2011