DS drove me nuts for an Ivy cap now he wants a cadet style hat. I couldn't find any patterns so I went to the stores and used the finger meausring system to get an idea and thought about it.
This is the prototype just so I could make sure it would work.
To print a pattern you can go to Wild Ginger and use the Sunhat pattern for your top and crown (that's how this hat started but the brim was crazy big so I tossed it to the garage). Then I used the newsboy brim all in size 22 for this particular hat. But remember you can adjust your H/L/W settings in Ginger.
#1 sew or serge crown piece together and attach to top
#2 sew outside of brim and flip, you can use interfacing or cardboard if you want it thick (this was a proto so I didn't bother and the denim is already thick)
the crown piece was to wide for what I wanted so I folded it in which looks out b/c in the pic it's seams out
#3 mark your centers for brim & crown & pin.Hat is inside out with the brim on the inside. your brim edges will be sticking out a bit. I put about a 2 inch piece of elastic in the back also. Sew around by 1/4 in
#4 I also sewed the brim/seam down & did another top stich line about an inch up (thats where my folded edge was) and I top stitched the crown seam down too
I hope you understand, it was pretty easy. I am going to make another one but use some nice fabric & grossgrin ribbon on the inside.