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You could use fusible interfacing, which would basically glue a very thin layer of stiffer fabric to the T-shirt fabric. That would make the T-shirt fabric easier to work with, and more fit for purpose as a cap fabric.

I haven't done this before with old T-shirts, so I can't guarantee the finish, but it should work, theoretically.

If you're very keen to give it a go, let's chat in PMs to arrange things?

Okay, great!

If you wouldn't mind placing the order via my Etsy shop - you'll see the custom cap listing - I'll order the fabric accordingly.

Yes, it is. Keep in mind that it's waxed cotton, which is a waterproof fabric.

If you're after a non-waterproof cap, I'd be happy to order the fabric, but it'll take a few extra days.

I can do do white/purple, no problems - you'd just have to indicate which colour each panel should be.

Since mine is a three-panel design, I'd suggest the side panels in one colour, and the central panel/strip in the contrasting colour.

That's perfect then.

I'll dig out my template cardboard . . .

Thanks so much!

I can make pretty much any brim shape/length/width, provided you have a clear idea of what you're after. You'll see a custom cap listing in my Etsy shop, which will allow for custom choices.

Cycling caps have a short brim to maintain forward and peripheral vision while riding, so that's something to keep in mind when choosing a larger brim.

The short answer is no, unfortunately.

I'd love to make upcycled casquettes, mind you, and for exactly the reason you touch on - there's a lot of nostalgia inherent in an item you've had for years.

But T-shirt fabric is an absolute PITA to sew with, and it's not an ideal fabric for making caps/hats because of the stretchiness.

Any piece of meaningful clothing made of something close to cotton twill (like chinos) or cotton poplin (like a button-up shirt) and I'm all in.

Great to hear that the cap fits. And thanks for the feedback on my question.

All of my earlier caps were made without liners, which leaves you with a single layer of cotton twill with a slim ribbon headband. It's about as breathable as a natural fibre cap gets, aside from making the whole thing out of cotton poplin - the liner fabric - which would be lighter and more breathable, but less hardwearing.

I'd be more than happy to whip one up for you in time for summer. Let's chat.

Chaps, what are your views on having the bold printed fabric on the inside vs the outside of your cycling cap?

If you've given my Etsy shop a test drive, you'll notice that most of my caps have a solid colour for the crown and printed fabric for the liner.

I've always liked it this way around because it's like each cap has a little something hidden away just for you. A bit of flash on the brim, of course.

But someone recently asked me to make their cap the other way around, with the bold print for the crown, and I really like it.

The head measurement is usually taken 1 cm above the ears around the head where the cap band would lie. So, if you're wanting to wear the cap lower at the back, then 59 cm it is.

Glorious! I'll make a note of the pattern size for future orders.

Looking forward to getting some long-term feedback on the utility of the waxed cotton.

I'm so pleased the replacement arrived!

You never mentioned whether it fits as it should?

I just spotted the order - thanks so much!

I'll wrap it up and have it with the courier after the school run.

That's great news - and thanks for letting me know.

If you have a moment, similar commentary on my Etsy shop would be greatly appreciated.

Looking forward to making the next one for you.

Happy cycling!

I do! What did you have in mind?

Thanks so much - I'm so glad you like them. Yep, it'll be a custom order. You'll see the listing on my Etsy shop.
You're also very welcome to send a PM on the forum.
Looking forward to hearing what you have in mind.

That's just the best! I'm so pleased it got to you safe and sound. Enjoy! And do let me know how the waxed cotton works out.

I see what you did there . . .

I can't guarantee suitability, but it'll fit like a glove!

None! I use SPDs on my road bikes, but I've always just ridden flats on the fixie. Never had a foot come off the pedals. Those RockBros platforms have got a lot of grip screws . . .

Nobody can compete with the Mig!

I'll have to let recent buyers post their own pics, but here's two of me. You'll see the deep fit of the cap and the angle of the peak, which makes the cap fit properly under a helmet. Flipped down, it's also not so low that it obscures your vision.

Thanks so much! I've just been asked the same by another person, and I'm happy to. I've done this for a few of my own casquettes - a new polypropylene sheet brim makes a great replacement.

Hey Andy. 80 cm x 40 cm for the outside (crown and peak) and the same again for the liner. My older pattern had a longer, traditional brim, so that's no problem to slot in. What sort of fabric do you have in mind?

Great stuff! Looking forward to breaking out those bigger patterns in the new year.

Just spotted the email notification - thanks so much for the order, Mark. I'll have that in the post to you directly.