- Nylon/polyester/other fabric
- Sewing needle/machine and thread
- Snap button
- Light cardboard/plastic
- Super glue
Measure the circumference and height of your head to determine the exact size cap to make. If you have an old cap lying around, use it as a guide to determine the size of the pieces you need.
Cut sturdy material like polyester or nylon into six long triangles based on your head or cap measurements. Sew these triangles together so they form a dome.
Attach a snap button (like one used on a jacket) to help seal the connection between the triangles at the very top of the cap. Apply a small amount of super glue to hold the button in place.
Poke and cut out small ventilation holes around the top of the cap. Make one hole for each triangle of fabric. Stitch thread around each hole to keep the fabric from fraying.
Cut a sheet of plastic or lightweight cardboard into the shape of a brim. This material needs to be soft enough for a sewing needle to penetrate. Cut two more pieces of fabric that will fit around the brim, sew them onto the top and bottom sides of the brim, then sew and/or glue the brim to the cap's front edge.
Embroider any lettering or other design you want onto the front of the cap.