I'm really into making things with old clothes. My sister had this old sweater in her Goodwill pile and I knew what I wanted to make the minute I saw it. I got the idea from Disney at Ruffles N Stuff , but I wanted to add a bill.
This is what came to my mind when trying to think of what to use for the bill. It's a small plastic cutting board I got at WalMart ages ago. It came in a pack of several different colors. I drew the outline by tracing another billed cap I had.
I used the bottom ribbing from front of the sweater for the bill. I cut two pieces and serged them together. I'm not sure if this would work without a serger.
I slipped the plastic bill in and sewed it up leaving a seam allowance to serge to the cap.
Next I cut the shape of the cap out using the ribbing at the bottom of the back of the sweater as the bottom of the cap. This allows it to stretch and keep it's shape.
I folded it over itself to make sure all the curves are the same. Then I serged up the sides.
I centered the bill on the front of the cap, pinned it and serged the right sides together.
Then I made and rosett with the original button in the middle and sewed it by hand to the front.