Question about Repairing a Hat/Cap

[dbaldock]

Hello all,

Here's a simple (I hope) question about repairing a hat/cap.

I've got a gray wool tweed driving cap, that looks more or less like this.  Since the cap is soft wool with silk satin lining, it's usually rolled and in a jacket pocket, to be handy if it's raining.

The problem is that the stiffening material in the bill has broken into two pieces.  I haven't tried to disassemble the cap, so I'm only guessing that the stiffener is probably a paper fiber or cardboard material.

I'm not really skilled at sewing (I can probably take the cap apart without destroying it, but not put it back together! ), so I'm wondering if there's anyone in the Houston, TX area who can replace the stiffener with something that, while still stiff, is more flexible and less likely to break?  Or, at least give me a good idea of what kind of material (probably plastic) to get.  Thanks!


Take Care,
David Baldock

EDIT: Added "satin"

[Zaubon]

If nobody here has any ideas, check with Miller's on North Main in Houston. http://www.millerhats.com/ They can probably recommed someone.

[Marietta Graziella]

What about using a flexible cutting mat for the bill?  I have purchased several from kids fund raisers at school and they are very flexible and could take the sutffing into the pocket bit.

If not that, check your local craft store for plastic grid.  That's what I use to support the sides of my taller hats with heavy plumage.

[escherblacksmith]

I will throw in my 2 cents and note that unless you have something designed to do this, most substances designed for stiffening don't take well to being rolled, stuffed, deformed, etc. 

Invariably they will either fail (like your current bill) or be reformed to the rolled up/crushed state, requiring work to go back to the way you liked.

I think you'd be better off to get the kind of hat/cap that doesn't require this sort of stiffening.  I'd say either a woolen beret-esque (sack) cap or a Tilley.  Which tend to be crushable.  I know I have beaten the hell out of mine.

[Lady Kathleen of Olmsted]

The old style Golf/Newsboy wool caps.

To repair this one would require the removal of the bill and then redone. That would be the job of a Milliner.

Or otherwise, order a new Hat.

[dbaldock]

The reason why I've got the driving cap with the small bill is to protect my glasses from the rain showers here in Houston.  Otherwise, I have to put on a ball cap - or take my glasses off.

[Randal]

It sounds to me as if the cap is already ruined, therefore you have nothing to lose by trying to repair it.

I would carefully pick the stitches apart, remove the defective stiffener, use the pieces as a pattern to cut a replacement out of "Fun Foam", or a piece of thick interfacing. I would then hand stitch everything back together, roll the cap up, and stuff it back in my jacket pocket, secure in the knowledge that my new stiffening material won't break.

Randal

[Aunty Lou]

The "fun foam" Randall mentions is a closed-cell foam sheet, about 1/8" thick, and can be found in the craft section of your stores along with the felt.  It is stiff enough for a soft cap brim, and quite flexible. (Able to be rolled...)  Think how secretly pleased you can be with flourescent orange on the inside of your cap's bill!

[Lady L]

Yes, I used the craft foam (found it at Joanne's and Walmart) inside the french hoods I made. Easy to sew through, easy to cut, not expensive, washable, held up just fine. I used the white, but it comes in a variety of colors. There are several thicknesses to choose from.

[dbaldock]

Thanks for all the suggestions.  Sounds like a project for me to tackle after the first of the year.

I can probably un-stitch enough of the brim/bill to get the old stiffener out, and cut a new piece of foam/plastic to replace it --- but I'm not at all confident in my ability to sew the cap back together so that it looks right and is comfortable on my forehead.  My previous sewing skills have been sewing a button back on a shirt, and I haven't done that in years.     

Take Care,
David Baldock

[iain robb]

I think folks are making this far too difficult.

Set the cap on a flat work surface, bottom side up.

Carefully measure the brim, front to back.

On the underside of the cap's brim, where NO ONE but you will see it, place three popsicle sticks, evenly spaced, across the bend/fold/break of the brim.

Cut two pieces of duct tape as long as the brim.

Place one piece of duct tape over the ends of three popsicle stick on one side of the break, pressing firmly.

Repeat on other side.

If you want to get fancy, you could use a Sharpie marker to duplicate the pattern of the hat on the duct tape and popsicle sticks.

But as I said, NO ONE will notice it, not at all. Well, OK, maybe some folks will notice it, but most will be too polite to say something. And even those who do will probably admire your craftsmanship. I'm sure there will be no sarcasm at all in their voices as they say, "Gee, I never would have thought of repairing a cap with popsicle sticks and duct tape."