Cycling Cap Sewing Pattern
 

I've posted a sewing pattern for a cycling cap at http://www.dillpicklegear.com/?page_id=219. It's downloadable for free, although if you like it please consider making a small donation to the League of American Bicyclists. It has two brim options and optional ear flaps, and works great in a wide variety of materials. It makes a great gift and you don't even have to mob the mall on Black Friday for it. :)

Nice Work! I'll have to try this.

What do you think would make a durable stiffener from the brim? Plastic foam sheeting?

Have you got a picture of a finished cap?

Cool thanks

I've had good results stiffening the brim with extra-heavy/ craft-weight interfacing. Doesn't really matter if it's fusible or not, because then I quilt through it with the sewing machine to keep everything sandwiched tight together. That makes it flexible but stiff enough to stay put in the wind.
Alternatively, you could use various kinds of plastic sheet such as thin polypropylene or polyethylene, or you could cut it out of the cover of a flexible plastic binder. I bet a thin sheet of closed-cell foam would work too, although you might want to test it to see what happens in the washer/dryer. Actually, that's never a bad idea no matter what you're using. ;)
I wouldn't use cardboard or paperboard, it disintegrates when wet. There probably are other things that could work, too.

There are a couple of photos of finished ones here: http://www.flickr.com/photos/lovely_...n/photostream/
I have more, that I've been meaning to put on the website....