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@tapsnbath
I made my first cycling cap last night:
http://www.flickr.com/photos/62771282@N06/7135304923/
I used an existing hat as a template as I don't have a pattern, and overall I'm quite happy with the results. The trim on the bill isn't quite lined up with the trim on the main part of the hat, but it's not too noticable. I followed the tip about using plastic packaging in the bill of the hat, earlier in this thread, and it's worked brilliantly as a stiffener!