How to Make a Welding Cap

Written by kim blakesley Google
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How to Make a Welding Cap
Use light weight denim to make a welding cap (denim texture #7 image by Adam Borkowski from

A welding cap is made of six triangles sewn together to create a dome. Adding a cap bill is optional. Zigzag around the bill to add strength. Do not add cardboard like most cap bills. All sizes of welding caps are made in the same fashion. Adjust the width and height of the triangles to make smaller and larger welding caps. Use a 1 1/2-inch seam tape around the bottom edge. The seam tape finishes the cap but also helps to absorb sweat. Use a printed twill or light weight denim to make a welding hat.

Skill level:

Things you need

  • Light weight denim
  • 7-inch small iron
  • Paper
  • Pencil
  • Scissors
  • Ruler
  • Sewing machine
  • Thread
  • 1 1/2-inch seam tape

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  1. 1

    Trace around the outside edge of a 7-inch iron's ironing surface. Locate the straight edge from the end of the iron on the tracing. Place a mark in the centre of the straight edge. Standard 7-inch irons are 3 1/4-inches wide. Place a mark at 1 5/8-inch.

  2. 2

    Measure down 1/4-inch from the centre mark just made. Start at a corner and bow the bottom edge to the mark. Bring the bow back up to the other edge.

  3. 3

    Make the tracing 1/2-inch larger on both bowed sides. Do not lengthen. Measure 1/2-inch from the two 7-inch bowed edges and place marks every inch. Measure up 1/2-inch from the top point and make a mark. Connect the marks. Cut out the template.

  4. 4

    Use light weight denim and cut out six of the templates.

  5. 5

    Pin two triangles together on the long curved edge. Use a 1/2 inch seam and sew the two triangles together. Pin and sew another triangle to the first two. Press the seams away from the centre triangle. Repeat the process and make a second set of three triangles.

  6. 6

    Work on the front of the fabric so the seam is underneath. Zigzag over the pressed fabric next to the finished seam. Repeat the process for a total of two zigzag seams on each set of three triangles.

  7. 7

    Pin the two sets of triangles together so the back side of the fabric is facing out. This will be the side that shows the edges of the fabric. Sew along the domed top edge of the hat with a 1/2-inch seam.

  8. 8

    Press both pieces of the seam to one side. Do not press open. Turn the hat so the raw edges of the seam are inside.

  9. 9

    Zigzag over the pressed fabric next to the finished seam. The zigzag seam will go from the front to the back of the welding hat.

  1. 1

    Lay the hat flat so three triangles are on each side. Place a 1/2-inch mark straight down from the front edge of the hat. Trace the bottom contour of the hat beginning 1 1/2 inches back from the first triangle's seam and connect it to the 1/2-inch mark. Remove the hat from the paper.

  2. 2

    Extend the 1/2-inch mark so it is 3 1/4-inches long. Start at the bottom of the 3 1/4 inch mark and curve it to the end of the traced line. Cut out the template. This is the bill template.

  3. 3

    Fold the lightweight denim. Place the straight line of the bill template on the fold. Pin into place. Cut out the fabric bill. Repeat for a total of two bills.

  4. 4

    Place the front sides of the fabric bill together. Pin along the outside edge of the bill. The outside edge is the freehand drawn curve on the bill. Sew the bill together using a 1/2 inch seam. Clip the curves on the seam. Flip the fabric so the raw edges of the seam is on the inside of the fabric. Press into place.

  5. 5

    Zigzag the sewn seam along the edge. Zigzag three more lines of stitching every 1/2-inch.

  1. 1

    Flip the hat body so the raw edges are facing out. Fold a 3/8-inch hem along the bottom raw edge of the hat. Pin into place and press.

  2. 2

    Fold the bill in half. Match the centre fold of the hat with the zigzag stitching that goes from the front to the back of the hat along the centre seam. Pin the raw edges of the hat bill to the bottom of the welding cap body. Use a 1/2-inch allowance and overlap the bottom of the hat body with the bill.

  3. 3

    Pin the 1 1/2-inch seam tape to the bottom edge of the hat body and cover the raw edges of the hat bill.

  4. 4

    Zigzag along the top and bottom edge of the seam tape.

  5. 5

    Flip the hat so the front side of the fabric is showing and all raw edges are on the inside. Clip all threads.

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