Stiffening hat brim

[Jerry Adams]

I have a boonie hat similar to this

https://www.rei.com/product/185858/ctr-boonie-hat?sku=1858580002&store=&CAWELAID=120217890011694184&CAGPSPN=pla&CAAGID=132179572493&CATCI=pla-1596562159110&cm_mmc=PLA_Google%7C21700000001700551_1858580002%7C1596562159110%7CNB%7C71700000079806808&gad_source=1&gclid=Cj0KCQiA3sq6BhD2ARIsAJ8MRwUxXBsC0NaNFeJmDdDMX2-DclqZmxR-UdL70QmVS3eecA_TMUpbDs4aArPqEALw_wcB&gclsrc=aw.ds

The brim is floppy so if it’s windy, it blows up and doesn’t shade my eyes

So, I got some stiffener similar to this:

https://www.joann.com/dw/image/v2/AAMM_PRD/on/demandware.static/-/Sites-joann-product-catalog/default/dwa61965c2/images/hi-res/12/1261502.jpg?sw=359&q=60

Then I cut that into a shape like the brim to a ball cap.  And some black fabric.  And sewed it onto the bottom of my boonie brim:

One trick is to cut it wider, like this red line:

And then when I sew it to the hat, pull it in.  Then the front of the brim will be pulled down so I get better sun protection.

I know, that red line is pathetic.  Maybe to the point you don’t understand what I’m talking about.  I need something better than paint and my mouse.

I’ve been trying to solve this problem for years.  Making various versions of a hat from scratch.  Nothing has been comfortable and effective.  This has worked pretty good on a number of windy trips.

[Scott Nelson]

I stiffened a full brimmed hat by sliding a piece of plastic weed whacker whip into the binding material on the edge of the brim.  I only put it on the front half of the hat and that lets me fold the hat for packing.  Metal wire might work also.

Scott

[Jerry Adams]

Good idea

I’ve used weed Wacker cord also

[Paul McLaughlin]

I think the geometry is as important as the stiffness. I have owned a couple of Columbia hats similar to the hat you have. And also a Sunday Afternoons hat which has a brim for about 180 degrees and a cape behind. The SA brim is far more wind resistant than the Columbia hats, and it looks to me like a more conical shape is the prime reason for that. When my current hat finally wears out I will cut the brim open to see what the stiffener is. It feels like some sort of dense foam, but I do not know where I would find such a material.

[Jerry Adams]

Maybe that product from Joanne’s.  I asked a different fabric store and that’s what they recommended

Yeah Paul, a conical shape will stay in place better.  Like Asian farmers in rice patties with conical bamboo hats.  Except just the brim.

By cutting the brim piece wide, like the pathetic red line I made, and then pulling it in to sew it on, it turns the brim into a conical shape.

[David Thomas]

I like the string trimmer cord idea – it’s available in many diameters.  If you want stiffness in only one axis, zip-ties could provide that.

I’ve also used solid copper wire in 14- or 12-gauge.  I saw it first in Arctic-rated down-filled work coveralls around the perimeter of its tunnel hood.  You can form it into whatever shape you want to allow for more or less visibility, wind/snow/cold air protection.

[Moab Randy]

I sew 14 ga insulated single-strand electrical wire around the brim of all my OR Sombriolet sun hats; without it, the hats are almost useless. Stops the wind problem and I can fold it down strategically to block sun. Someday I’ll start a tread on it.

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