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It's quite easy actually to add a bill to a cap. I used a favorite cap pattern, knit on my bulky machine with 80 sts at T9 with a bulky yarn. This particular cap features a non-stretchy band, which I doubled in length to accomodate a fold over band. If I were putting a bill on a stretchy band such as ribbing, I probably would stabilize the front part of the band before attaching the bill, maybe with a slip stitch at the fold line or something similar. So I made the hat and added the bill like this:
1) Fold the
band in half lengthwise and loosely
down to the beginning row of the hat body, picking up
inner edge stitch loop of the band only.
2) With wrong side facing, hang 30 sts from
center of the hat band. Somewhat stretch the
band while picking up stitches.
3) T9, K1R
4) RC000, Put
machine on hold. On carriage side, bring
first working needle to hold position. T8, Knit across.
on the right hand side.
to shortrow decrease in this manner with the following needles on each side:
1, 2, 1, 2, 1 = 24 rows (8 sts on each
side in HP, 14 sts in work in center)
7) When the
same number of needles are in HP on each side, reverse the shaping to increase
in the same
order as above (1, 2, 1, 2, 1, 1) until all needles are back into work, except 1 on each side. Put both needles into
working position and knit across. Wrap
the 1st needle on carriage side on each pass to prevent holes. Leave a long tail of yarn for sewing.
8) Scrap off with several rows of waste yarn.
9) Insert a 'moon' shaped piece of heavy
Pellon interfacing between the layers and pin in place. Just a note that the more rounded the 'moon' shape is against the head, the less it will flop down.
10) Evenly across, blanket stitch each live stitch of the bill to the first stitch of the band. Remove waste yarn.
11) After the bill has been sewn down with the Pellon inserted, inconspicuously tack in
several places on the underside of the bill with a sewing needle and thread to hold the Pellon in place during wearing and laundry.
12) Work 1
row of crocheted (latch tool) slip stitch on the inside of the bill, going thru
each stitch of the bill
and picking up a stitch from the inside layer of the band. This will keep it from stretching and to help keep
the bill from flopping down.