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Aviator Cap Sample Completed! (pics)

cycler1729 | Posted in General Discussion on

Thanks to everyone who answered my questions!  For this first version, I adapted my swim cap pattern almost doubling the size because that pattern had to stretch a lot to fit snugly.

I then sewed a muslin (a first for me) and, interestingly, because I didn’t think to lengthen the center panel, it came out to the right length and showed me where to cut the sides. 

When I was at my favorite fabric store a couple of weeks ago the owner was cutting a big piece off the end of a bolt of quilted velveteen because it was damaged and he asked me if I wanted it (of course I said yes – and that’s also why it is my favorite fabric store – they treat me so well!) and it was perfect for this cap!

I didn’t line it (I didn’t think of it until I had finished but I will line the next one) and I had trouble sewing a buttonhole on a double thickness of the leather (it’s an older machine) or even on a double thickness of the fabric so the strap is just a single thickness.  I thought about it afterwards and I think that if I cut 2 bigger strips and sew a buttonhole on each and then match them afterwards that might work. 

I also had to adjust the back at the neck because it wasn’t until I wore it that I realized how much it stayed away from my head so I adjusted the seams to curve inward instead of straight down.

<a href=”http://i8.photobucket.com/albums/a42/wrdsandmusic/100_5886.jpg” target=”_blank”>

<a href=”http://i8.photobucket.com/albums/a42/wrdsandmusic/100_5887.jpg” target=”_blank”>

<a href=”http://i8.photobucket.com/albums/a42/wrdsandmusic/100_5888.jpg” target=”_blank”>



Edited 10/8/2008 11:49 am ET by cycler1729

Edited 10/8/2008 11:50 am ET by cycler1729


  1. MaryinColorado | | #1

    Susan, you're hat looks great, and so do you!  How did you end up adjusting the back to fit?  Darts?  Elastic?  You are a clever gal, so happy your ears will be warm and toasty as you brave the streets of NY on your bike.  Bravo!!!

    1. User avater
      ThreadKoe | | #2

      Susan, you and your hat look just FINE! Super job! And fashionable too! I really, really, really like it.Got a hint for your next one. To help fit the hat snugly to your head, use grosgrain ribbon sewn inside the brim. Measure a piece if 3/4 or 1 inch wide to fit securely around your head, and sew into a circle. Then handsew it into the inside of the hat(just along one edge), around the edge of the brim, easing the brim to fit. If the hat has flaps, this will help keep the flaps from flipping up as well. Then the chinstrap will become more decorative, and not the only thing keeping your hat on. This will also absorb sweat and is easily removed and replaced as needed to protect your hat. Cathy

      1. cycler1729 | | #4

        Thanks for all of the positive comments!

        I adjusted the back by re-sewing the side seams from about 4" from the bottom, angling in so it curved to my neck.  I'll re-sew the muslin and cut off the excess and then cut a new pattern from that. 

        I usually use grosgrain ribbon on my brimmed hats to hide the seam where the brim meets the top and you are right  - I ought to've used it on this one too but I didn't think of it. 

        There are so many ways to finish this - to sew a lining that is the same as the cap and sew along the edges and then turn letting the strap come out from between the layers or adding a leather binding all around and extending the strap from there - I love thinking about all of the different ideas! 

        1. MaryinColorado | | #5

          This is such an interesting project.  I've enjoyed all the thought processes that go along with it.  I'm so glad that you came up with it and are sharing your experiences as you go along.

          I wonder if you could put a buttonhole in one side and run the strap through that instead of having to sew it onto the hat?  It could be adjustable or not.  Mary

          1. cycler1729 | | #6

            I was thinking about those metal belt thingys - where you put the strap over one and under another and it holds it in place.  I don't see them in my supplies catalogue so I'll need to keep looking.

            But my teflon foot finally arrived so that ought to simplify sewing the leather.

          2. MaryinColorado | | #7

            Did you try the teflon foot yet?  I haven't used it on real leather yet, but it does help the fake leather to glide under the foot, so I think it will be great for you.  Hope so.  Did you use leather needles too?  We turned on the furnace.  I sure hope the squirrel that's been running around carrying things up to the roof didn't make a nest in the chimney.  We usually just use the fireplace until it's really cold but I'm kind of afraid to do that now.  Did you see the movie, "Christmas Vacation" with the wild squirrel inthe house?  ha ha, not my idea of a fun time....

          3. cycler1729 | | #8

            I didn't get to use the foot yet - my sewing has to wait a while because I've got a lot of work to get done in the next 2 months unfortunately.

            I commiserate about the squirrel - last year we had mice in all of the apartments on my floor and we did everything possible - I even bought those electronic repellers.   Everything was great until yesterday - one popped out from behind my bookshelves!  Back to square one.

            We kid about squirrels in NYC - the ones who "live" in the nicer neighborhoods are healthy looking but the ones in Tompkins Square Park look like little drug addicts!

          4. MaryinColorado | | #10

            Oh, that's so sad, poor little .... oh yeah, we are talking about rodents aren't we?  I remember rats in DC near the bus depot, were as big as cats, very scary...when I made the mistake of taking a bus there from Pa. at night!  I was 18 and didn't know any better, but learned fast!  Don't know to this day how I managed to survive my youth, but glad I did.  My guardian angel was definitely working overtime!  Mary

          5. User avater
            ThreadKoe | | #9

            Are you thinking of using the metal D rings?  I have them on my motorcycle helmet and they are a pain in the *&&.  You would be better off using one of the insertable clip fasteners like they use on back packs,  they sell ones that you can attach to the D rings on helmets to make taking them on and off easier.  They also cost about the same as the D rings and are easier to sew on the straps.  Cathy

          6. cycler1729 | | #11

            Thanks for the info - I will forget about those.  A button still seems to be the easiest but I was also looking at the bigger size jewelry findings - something like a giant hook and eye.  Since the cap is so simple, I like unusual closings. 

          7. User avater
            ThreadKoe | | #12

            A large lobster claw clasp would be an unusual and easy closure.  Not too bulky either.  Interesting thought.  Cathy

          8. cycler1729 | | #13

            And a great excuse to buy lots of gorgeous findings!  I love the look of them - especially in an unusual shape.

          9. User avater
            ThreadKoe | | #14

            My problem is yard sales.  I buy nice old necklaces just for the unusual beads and findings and repurpose them in my christmas ornaments.  Like I need another reason to add to my stash!   LOL  Cathy

  2. rodezzy | | #3

    Great job and great hat. 

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