How to Make Welding Caps? 14 Steps

Welders must have some equipment to keep themselves safe from the adverse impact of welding. Among various tools, welding caps are one of the important things for maintaining safety.

A welding cap is a necessary thing for welders. It helps the welders to protect their necks and ears. This safety equipment also gives protection to your hair. There are various kinds of hats or caps available in the market. You can buy any of them.

Moreover, making welding caps is also not so hard. You can easily find the proper clothes and other materials to make the welding caps on your own. So, how to make welding caps? Maybe you need the answer to this question so that you can easily make it for yourself.

So, let’s start with the process of making welding caps.

Make your own welding cap

Homemade welding caps are very popular nowadays. If you know how to sew, then you can easily make it. The steps of making welding caps are given below:

Step -1: Collect the things you will need

¼ yard of the outer cloth
¼ yard of lining cloth
Batting scarp
Thread
Pattern for welding cap

Step -2: Cut off the pattern and place it on the welding cloth

In this section, you have to cut the pattern into the pieces and place it nicely on the cloth for further procedure.

Step -3: Cut the fabric according to the pattern pieces

You need to follow the direction of the patterns to cut off the cloth nicely.

Step-4: Cut the fabric of your welding cloth

Now, you have to cut the fabric in the shape of the pattern. You have to follow the number of the pattern pieces carefully. Otherwise, it will not be perfect.

Another thing you should remember is that you have to take the exact measurement of your headband. If you cut it according to the pattern, then it will not be well fitted.

Step-5: Gather all the cutting pieces of your cloth

Now, you have to assemble all the pieces that you already have cut. It’s actually your assembling time.

Step-6: Interfacing

Keep an oversized interfacing piece to set the cloth pieces. Then iron all the pieces for getting a better result.

Step-7: sew the side pieces together

You have to attach the lining pieces together. Just sew a line for attaching them together. You have to sew the outer part in the same way.

Step-8: sew the front and back pieces

Now, stitch the side pieces front and back nicely.

Step-9: make ready the dome

Create a bowl shape for getting ready for your dome. Make two domes and attach them with the welding cap.

Step-10: make and finish the billing

Place two bills appropriately. Sew half curve cage for building the bill. Make it and finish it appropriately.

Step -11: sew the band pieces

Draw some dots and stitch the band pieces for getting the perfect shape for your welding caps.

Step-12: attach the band with the bill

Now, you have to attach the band with the bill and finish the bill.

Step 13: attach the inner dome and outer dome

Step 14: check out the new welding cap

What fabric is best for welding caps?

There are various kinds of clothes available in the market. Among them, cotton is the best for making welding caps. You should pick such a kind of fabric that is hard and strong enough to hold your head.

You should avoid nylon, polyester, or any kind of this material for your welding caps. The cotton-made welding caps are summer friendly, breathable and you can use them with comfort.

Welding cap measurements

The measurement of the welding cap depends on the measurement of your head basically. There are some techniques to take the proper measurement.

In this section, I will discuss how easily you can get the actual measures for making the welding caps. So let’s begin:

Measurement process:

First, place the end of the tape in the middle of the forehead. Take note of the measurement. If you use metallic tape, then you should use string.

After that, you should wrap the measurement tape around the head until it returns to the point where you start. You should go up to your ears. At this point, your hat would take to rest.

The measurement should be well fitted whereas you take it with tape or string. Too much tight or too much loose won’t work. It is needed to be comfortable enough and just fitted nicely to stay on the head properly.

You should take all the measurements in inches.

Then, there are lots of size charts available, you can take measurements from them. If you find yourself in between the size, then always pick on size large for well-fitted.

Measurement process of crown head:

You should take measurements from the highest peak (crown) of your head and end at the place where the bottom of the band is to be placed.

You can also take measurements if you have a well-fitted hat. Just lay down it on a plain surface and take measurements of the crown of the hat.

For betterment, here a welding cup sizing chart is given below:

Cup Size	63/4	67/8	7	71/8	71/4	73/8	71/2	75/8	73/4	77/8	8
Head Measurement	211/8	211/2	217/8	221/4	225/8	23	231/2	237/8	241/4	245/8	25

Where to buy welding cap patterns?

You can get various kinds of patterns such as 4-panel patterns, 6-panel patterns, reversible, and Comeaux for welding caps. The 6-panel welding cap pattern is very good for making a perfect-shaped cap.

Many reputed websites, online stores, and physical stores have a vast collection of different-shaped welding caps.

Etsy is a website where you get a good amount of pieces of stuff for welding caps. Then all the reputed stores like amazon, and Alibaba have trendy designs in welding caps. You can check out them to get a good quality product for welding caps.

Verdict

Nowadays, welding is a very necessary thing for industrial things. Welders have done things with lots of health risks. That’s why using proper equipment is a must-have.

A welding cap is one of them. You can buy it from various reputable shops or if you want to make it on your own, then this would be perfectly fine.

Hopefully, the article about how to make welding caps covers all the necessary things that you have to know before going to make a welding cap.