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  3. 22 Steps to Perfection
Step 1: Cutting Room

CUTTING ROOM

Step 1: Fabric Is cut.

CUTTING ROOM

Step 1: Fabric Is cut.

Step 2: Bundling

BUNDLING

Step 2: Pieces are bundled together to create cap.

BUNDLING

Step 2: Pieces are bundled together to create cap.

Step 3: Sew Front Back

SEW FRONT BACK

Step 3: Front and back panels are sewn together.

SEW FRONT BACK

Step 3: Front and back panels are sewn together.

Step 4: Tape Front Back

TAPE FRONT BACK

Step 4: Fabric is applied to the front and back seams to cover exposed edges.

TAPE FRONT BACK

Step 4: Fabric is applied to the front and back seams to cover exposed edges.

Step 5: Haircloth Covers

HAIRCLOTH COVERS

Step 5: Two panels of haircloth fabric are sewn together.

HAIRCLOTH COVERS

Step 5: Two panels of haircloth fabric are sewn together.

Step 6: Haircloth Tape

HAIRCLOTH TAPE

Step 6: As in Step 4, Fabric is applied

HAIRCLOTH TAPE

Step 6: As in Step 4, Fabric is applied

Step 7: Peak Made

PEAK MADE

Step 7: The visor fabric is sewn together with a visor board inserted in between.

PEAK MADE

Step 7: The visor fabric is sewn together with a visor board inserted in between.

Step 8: Peak Stitch

PEAK STITCH

Step 8: Approximately eight rows of stitching are applied to the visor.

PEAK STITCH

Step 8: Approximately eight rows of stitching are applied to the visor.

Step 9: Embroidery

EMBROIDERY

Step 9: Logos are added.

EMBROIDERY

Step 9: Logos are added.

Step 10: Fusing

FUSING

Step 10: TOP SECRET!

FUSING

Step 10: TOP SECRET!

Step 11: Eyelets

EYELETS

Step 11: The stitching is sewn around the pre-punched eyelet hole.

EYELETS

Step 11: The stitching is sewn around the pre-punched eyelet hole.

Step 12: Covers

COVERS

Step 12: The crown is created with a middle panel sewn to the front and back panels.

COVERS

Step 12: The crown is created with a middle panel sewn to the front and back panels.

Step 13: Complete Tape

COMPLETE TAPE

Step 13: As in Steps 4 and 6, fabric is then applied to the seams.

COMPLETE TAPE

Step 13: As in Steps 4 and 6, fabric is then applied to the seams.

Step 14: Sizing

SIZING

Step 14: A premeasured strip is applied to the base of the crown to make it a specific size.

SIZING

Step 14: A premeasured strip is applied to the base of the crown to make it a specific size.

Step 15: Attach Peak

ATTACH PEAK

Step 15: The crown and visor are attached.

ATTACH PEAK

Step 15: The crown and visor are attached.

Step 16: Attach Sweat Band

ATTACH SWEAT BAND

Step 16: Sweatband is added to the base of the crown.

ATTACH

SWEAT BAND

Step 16: Sweatband is added to the base of the crown.

Step 17: Bartacks Label

BARTACKS LABEL

Step 17: Labels are sewn evenly together.

BARTACKS LABEL

Step 17: Labels are sewn evenly together.

Step 18: Top Stitch

TOP STITCH

Step 18: Decorative top stitch is applied to the base of the cap.

TOP STITCH

Step 18: Decorative top stitch is applied to the base of the cap.

Step 19: Buttons

BUTTONS

Step 19: A button is applied to the top of the cap.

BUTTONS

Step 19: A button is applied to the top of the cap.

Step 20: Blocking

BLOCKING

Step 20: The cap is placed on a blocking machine to ensure size, steamed and placed on a cooling rack.

BLOCKING

Step 20: The cap is placed on a blocking machine to ensure size, steamed and placed on a cooling rack.

Step 21: Packing

PACKING

Step 21: The cap is packed with a visor sticker after final inspection.

PACKING

Step 21: The cap is packed with a visor sticker after final inspection.

Step 22: The Perfect Cap

THE PERFECT CAP

THE PERFECT CAP