So my man randomly told me that he thought cycling caps were really cool (he's into bike everything - he's training for a double marathon). After looking at them and finding a pattern here, I decided that I'd try my hand at hat-making. I think it turned out pretty good.
The pattern, even in "original" size, was not the correct dimensions. After tweaking it in my own document to meet the dimensions it lists, I then printed it out. I found a used wool jacket from the SPCA thrift store for $6. I cut out the lining and then cut it up for its new look. My husband has a fairly large head, he usually wears a 7 5/8 hat size. This hat worked perfect for him because it didn't require me inserting any elastic on the back. If you make this for a smaller head, you will either want to tweak the pattern or put elastic in the back. After sewing the 4 larger pieces together, I sewed the top and bottom bill pieces together on the curve and then flipped it inside out. I cut out a piece of plastic from the front of an old binder and inserted it in the pocket. (Decide at this point how much you want to fold under the bottom raw edge around the sides of the hat - do this by trying it on.) Match the raw edge of the bill to the raw edge of the bottom of the hat and sew right along the edge of the plastic. Tuck the rest of the raw edge up and sew all around the bottom of the hat to hold the seam, including the raw edges of the bill piece. Good luck! If you have any questions, feel free to ask.
*On the next hat I will be making a bigger bill.