Deschutes Redside Trout Trucker Hat

by @sunny

Clear of the water, canyon all around.

A rainbow trout leaping a canyon river in rose red, olive and turquoise, painted as a full scene for a trucker hat.

A rainbow trout leaps clear of a turquoise river between tan canyon walls under a clouded blue sky. It is coloured in olive green, cream and a rose red stripe, with sage green brush on the banks.

  • Leaping rainbow trout with rose red stripe
  • Tan canyon walls and sage green brush
  • Turquoise river with white spray
  • Blue sky with soft white clouds
  • Eleven colour layers, sky to highlight

The cap

One design, four caps. The front panel is what the paint or the dye sits on, so it changes the hat.

  • A blank Trucker cap

    Trucker

    The house cap — structured mid profile, foam-and-mesh back, snapback.

    Specs
    Profile
    Mid profile
    Build
    6-panel · Structured — buckram behind the front
    Crown
    3½ in (8.9 cm)
    Visor
    Pre-curved, 2¾ in (7 cm)
    Closure
    Snapback
    Adjusts to
    21½–24 in (54.5–61 cm)
    Airbrushed on
    Natural cotton twill
    Sublimated on
    White polyester foam
  • A blank Rope cap

    Rope cap

    Structured five-panel with a near-flat brim and a cord across it.

    Specs
    Profile
    Mid-high profile
    Build
    5-panel · Structured
    Crown
    4 in (10.2 cm)
    Visor
    Near-flat, 2⅞ in (7.3 cm), contrast rope
    Closure
    Snapback
    Adjusts to
    21½–23¾ in (54.5–60.5 cm)
    Airbrushed on
    Stone cotton twill
    Sublimated on
    White polyester twill
  • A blank Dad hat

    Dad hat

    Soft, low and unstructured — washed cotton with a strap back.

    Specs
    Profile
    Low profile
    Build
    6-panel · Unstructured — soft front
    Crown
    3¼ in (8.3 cm)
    Visor
    Curved, 2¾ in (7 cm)
    Closure
    Strap back, brass buckle
    Adjusts to
    21–23½ in (53.5–59.5 cm)
    Airbrushed on
    Washed khaki cotton
    Sublimated on
    White polyester twill
  • A blank Five-panel camp cap

    Five-panel camp

    Flat brim, low crown, packs flat in a vest pocket.

    Specs
    Profile
    Low profile
    Build
    5-panel · Unstructured
    Crown
    3¼ in (8.3 cm)
    Visor
    Flat, 2½ in (6.4 cm)
    Closure
    Strap back, side-release clip
    Adjusts to
    21½–23½ in (54.5–59.5 cm)
    Airbrushed on
    Field olive nylon-cotton
    Sublimated on
    White polyester

Fit

A cloth tape measure around the crown of a blank cap
CapProfileCrown heightVisorAdjusts to
TruckerMid profile3½ in (8.9 cm)Pre-curved, 2¾ in (7 cm)21½–24 in (54.5–61 cm)
Rope capMid-high profile4 in (10.2 cm)Near-flat, 2⅞ in (7.3 cm), contrast rope21½–23¾ in (54.5–60.5 cm)
Dad hatLow profile3¼ in (8.3 cm)Curved, 2¾ in (7 cm)21–23½ in (53.5–59.5 cm)
Five-panel campLow profile3¼ in (8.3 cm)Flat, 2½ in (6.4 cm)21½–23½ in (54.5–59.5 cm)

One size per cap. Run a tape around your head just above the ears, keeping it level — anything inside the range above will close on it.

Two finishes

The same design, made two ways. Pick one in the panel; the cap and the quantity are yours to choose too.

  • An airbrush misting pigment through a stencil onto a cap panel

    Hand airbrushed

    $85 for one hat, on a trucker

    Painted to order — would ship in about 2 weeks

    How it is made
    How it is made
    Sprayed by hand through this design's own stencils, one layer at a time, each left to dry before the next mask goes down.
    How it looks
    Soft gradients and hand-cut stencil edges. Every cap is a little different.
    What it sits on
    On a natural cotton twill front.
    Durability and care
    Water-based paint, heat set and sealed. It takes rain and a season on a boat; spot clean with cool water, never a washing machine.
  • A sublimation-printed cap panel peeled from the transfer sheet

    Sublimation printed

    $32 for one hat, on a trucker

    Printed to order — would ship in 5–7 business days

    How it is made
    How it is made
    The design is printed in dye onto transfer paper, then pressed with heat so the dye soaks into the polyester fibres.
    How it looks
    Full colour edge to edge, and identical every time.
    What it sits on
    On a white polyester foam front — sublimation only takes on white polyester.
    Durability and care
    The dye is in the fibre, not on it, so it will not crack or peel. Gentle wash, air dry.

The artwork

A redside rainbow trout arcs out of fast turquoise water. Its rose red stripe runs nose to tail over an olive back and cream belly, all freckled with dark spots. Behind it, tan cliffs stack up under a blue sky and white clouds, with sage green brush on the banks.

It reads well across a parking lot at the put-in and up close at the fly shop counter. The colours sit happily with river dust, sun and a long drift day. People tend to ask which river it is.

The rose red band is what makes it a redside. Lay it in thin passes over the olive and cream so the edges blur a little into the flank, then add the charcoal spots on top so they sit over the stripe, not under it.

The water it was painted from

The Deschutes River

Deschutes RiverCentral Oregon · OR

River
Deschutes River, Central Oregon
States
OR
Fish
Redside rainbow trout, Summer steelhead
Water type
Freestone
A cap in tissue in an open kraft box

What arrives

  • The hat
  • A care card
  • On a hand airbrushed hat, a numbered tag naming the water it was painted from, when the design names one
A cap being spot-cleaned with a soft brush

Looking after it

Hand airbrushed

  • Spot clean with cool water and a soft brush. Never a washing machine.
  • Keep it out of a hot car for long stretches — heat-set paint is tough, but a dashboard in July is not a test worth running.
  • Reshape the brim by hand while damp.

Sublimation printed

  • Spot clean, or gently hand wash in cool water. No bleach.
  • Air dry. Do not iron the print.
  • Reshape the brim by hand while damp.
  • The dye is in the fibre, so the print will not crack or peel.

Details

Airbrush palette

Colours
sky blue, cloud white, sandstone tan, canyon brown, sage green, river turquoise, olive green, cream, rose red, charcoal

Details

Subject
rainbow trout
Style
painted canyon scene

Make it yourself

A hat-painting bench with a blank cap, stencils and an airbrush

IntermediateAbout 5 hours at the bench, plus curing11 layersYou'll need an airbrush, a cap jig and 10 colours

The palette

  • Sky blue
  • Cloud white
  • Sandstone tan
  • Canyon brown
  • Sage green
  • River turquoise
  • Olive green
  • Cream
  • Rose red
  • Charcoal

The layers

11 layers, in this order. Each mask comes off and the paint has to dry before the next one goes down.

  1. Sky
  2. Clouds
  3. Canyon walls
  4. Rock shadow
  5. Sagebrush
  6. River
  7. Trout back
  8. Belly
  9. Redside band
  10. Spots and edges
  11. Highlights

The kit's stencil set is cut from these layers; with the cutter (12 hats and up) you cut your own from this design's layer files.

How to mix each colour

  • Sky blue

    1 part blue to 4 parts white, a drop of green so it does not drift purple

  • Cloud white

    Opaque white from the bottle; two thin coats cover better than one thick one

  • Sandstone tan

    3 parts white, 2 parts yellow, 1 part brown

  • Canyon brown

    Equal parts red, yellow and blue, then a drop of black to deepen it; or burnt umber straight from the bottle

  • Sage green

    2 parts green, 1 part white, a drop of black to dull it

  • River turquoise

    1 part blue, 1 part green, 2 parts white; a drop of yellow if it looks too cold

  • Olive green

    2 parts yellow, 1 part black, a drop of red to warm it

  • Cream

    White with a drop of yellow and the smallest touch of brown

  • Rose red

    1 part red to 4 parts white, a drop of blue if it looks salmon

  • Charcoal

    1 part white to 3 parts black, a drop of blue

Setup

  • Ventilation or a spray booth. Water-based paint still throws a fine mist, and you will be breathing it for hours.
  • A half-mask respirator rated for paint mists. A dust mask is not one.
  • A compressor with a moisture trap, set and tested on a card before you start: wet air spits water into the paint.
  • Reducer and a cleaning pot within reach, so a clog is a ten-second fix instead of a ruined panel.
  • Spray a test card for every colour before it touches the cap. Colour reads differently wet, dry and on twill.

Prep

  • Lint-roll the front panel. Every fibre left on it prints as a speck in the paint.
  • Mask the mesh, any seams you want clean and the whole visor, underside included, with low-tack tape and paper.
  • Stretch the crown over the cap jig so the front panel is taut and curved the way it will be worn. Spraying a slack panel flat distorts the design when it is worn.
  • Spray one light coat of transparent base so the colour sits on the fabric instead of soaking into it.

Layer by layer

  1. 1 · Sky — 0.5 mm · 25–30 PSI

    sky blue — a clouded sky across the top of the scene

    Mask None on the panel itself: the mesh and the visor are already masked from the prep.

    Colour Sky blue — 1 part blue to 4 parts white, a drop of green so it does not drift purple

    Needle
    0.5 mm (a 0.35 mm works, it just takes longer)
    Pressure
    25–30 PSI
    Distance
    6–8 in from the panel
    Passes
    3–4 light passes, building the colour
    Dry
    10 minutes, or 60–90 seconds with a heat gun on low, before the next mask goes down

    Tip Fade wet to dry and never lay one heavy coat: twill wicks paint sideways and the edge blooms.

  2. 2 · Clouds — 0.35 mm · 20–25 PSI

    cloud white — soft drifting clouds over the canyon rim

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Cloud white — Opaque white from the bottle; two thin coats cover better than one thick one

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  3. 3 · Canyon walls — 0.35 mm · 20–25 PSI

    sandstone tan — layered cliffs rising on both sides

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Sandstone tan — 3 parts white, 2 parts yellow, 1 part brown

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  4. 4 · Rock shadow — 0.35 mm · 20–25 PSI

    canyon brown — seams, ledges and shadowed cliff faces

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Canyon brown — Equal parts red, yellow and blue, then a drop of black to deepen it; or burnt umber straight from the bottle

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  5. 5 · Sagebrush — 0.35 mm · 20–25 PSI

    sage green — brush clumps along both banks

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Sage green — 2 parts green, 1 part white, a drop of black to dull it

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  6. 6 · River — 0.35 mm · 20–25 PSI

    river turquoise — fast water filling the bottom of the scene

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour River turquoise — 1 part blue, 1 part green, 2 parts white; a drop of yellow if it looks too cold

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  7. 7 · Trout back — 0.3 mm · 18–22 PSI

    olive green — the back and upper flank of the leaping trout

    Mask The hand-cut subject stencil, inner pieces first, then the outline piece.

    Colour Olive green — 2 parts yellow, 1 part black, a drop of red to warm it

    Needle
    0.3 mm
    Pressure
    18–22 PSI
    Distance
    3–4 in from the panel
    Passes
    2–3 passes per tone, light to dark
    Dry
    10 minutes between tones

    Tip Light tones first: a light colour over a dark one needs many coats, a dark one over a light one needs two.

  8. 8 · Belly — 0.35 mm · 20–25 PSI

    cream — the lower flank and belly

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Cream — White with a drop of yellow and the smallest touch of brown

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  9. 9 · Redside band — 0.35 mm · 20–25 PSI

    rose red — the lateral stripe and gill plate

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Rose red — 1 part red to 4 parts white, a drop of blue if it looks salmon

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  10. 10 · Spots and edges — 0.35 mm · 20–25 PSI

    charcoal — spots, fin edges, eye and outline

    Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.

    Colour Charcoal — 1 part white to 3 parts black, a drop of blue

    Needle
    0.35 mm
    Pressure
    20–25 PSI
    Distance
    4–6 in from the panel
    Passes
    2–3 passes
    Dry
    10 minutes before lifting the stencil

    Tip Spray away from the stencil edge, not into it, so the air does not push paint underneath.

  11. 11 · Highlights — 0.2–0.3 mm · 12–15 PSI

    cloud white — spray, foam and the glint in the eye

    Mask None: freehand, with a shield card held against any hard edge.

    Colour Cloud white — Opaque white from the bottle; two thin coats cover better than one thick one

    Needle
    0.2–0.3 mm
    Pressure
    12–15 PSI
    Distance
    1–2 in from the panel
    Passes
    Freehand, in short controlled strokes
    Dry
    10 minutes, then check it before you cure

    Tip Low pressure, close in and moving: stop the stroke before you release the trigger.

Step by step

  1. Mask the trout silhouette and the cliff outlines. Spray sky blue across the top at about 20 PSI with a 0.5 mm needle from 15 cm. Treat every setting here as a starting point and test on scrap first.

  2. Drop to about 15 PSI and float cloud white clouds freehand or with a torn-paper mask from 10 cm, leaving blue showing between them.

  3. Mask the sky. Spray sandstone tan over both canyon walls at about 18 PSI, 0.5 mm needle, 12 cm.

  4. Use a ledge stencil and spray canyon brown along seams and shadowed faces at about 15 PSI with a 0.3 mm needle from 8 cm.

  5. With a loose brush-shape stencil, dab sage green clumps along both banks at about 15 PSI, 0.3 mm needle, 8 cm.

  6. Mask the banks and fish. Spray river turquoise across the water at about 20 PSI, 0.5 mm needle, 12 cm, darker toward the bottom edge.

  7. Remove the trout mask and cover the scene. Spray olive green along the back and upper flank at about 15 PSI, 0.3 mm needle, 8 cm.

  8. Spray cream along the belly and lower flank at the same settings, letting it soften into the olive.

  9. Spray the rose red stripe and gill plate in thin passes at about 12 PSI, 0.3 mm needle, 6 cm.

  10. Add charcoal spots, fin edges, the eye and outline at about 12 PSI with a 0.2 mm needle from 4 cm, using a spot stencil or steady freehand.

  11. Finish with cloud white spray around the fish, foam in the water and a glint in the eye at about 10 PSI, 0.2 mm needle, 3 cm.

  12. Let the paint cure fully according to your paint maker's directions, then heat set and seal as they recommend.

Cure

  • Heat set at 300°F / 150°C. Water-based textile paint is not wash-fast until it is heat set.
  • Cap press: 3–5 minutes with a teflon sheet over the design.
  • Or heat gun: 2–3 minutes per panel, keeping it moving 2–3 in off the fabric so it does not scorch.
  • If you have neither, air cure for 72 hours before the cap touches water.

Seal

  • Two light coats of matte fabric sealer, UV-resistant, from 8–10 in, 15 minutes apart.
  • Leave it 24 hours before the cap is worn.
  • Never a gloss sealer on cotton twill: it shines, cracks along the creases and looks like a sticker.

Clean-up

  • Flush the brush with water, then airbrush cleaner, until it sprays clear.
  • Strip the needle and wipe it toward the tip, never away from it.
  • Never soak the brush body overnight.

Common mistakes

  • Heavy rose red goes flat and brick-coloured. Build it in three or four light passes and stop early.
  • Spots laid before the stripe disappear under it. Always spray charcoal after the rose red.
  • Hard mask edges on the clouds look cut out. Lift the mask slightly or use torn paper for a soft edge.
  • Rushing the cure leads to smudged highlights. Give each colour time to dry before the next mask goes down.

Tips

  • Spray the turquoise river darker at the bottom and lighter near the fish so the leap reads against bright water.
  • Keep the charcoal spots small near the head and a touch larger toward the tail for a natural pattern.
  • Leave a sliver of cream between the red stripe and the belly so the stripe glows instead of going muddy.
An airbrush, compressor, moisture trap, six colour bottles and a cleaning pot.
The kit

Every kit size

Trucker · kit for 1 hat

$229

Bought separately $255 · you save $26

Includes Starter airbrush set · Cap jig · and 7 more

Every item in this kit · 9 items

Blanks

  • Trucker blank, natural cotton twill front$91

Stencils

  • Pre-cut mylar stencil set for this design — 11 layers$181

Paint & masks

  • Water-based textile airbrush colour, 2 oz — one per colour in this design$482 oz × 8
  • Transparent base and reducer, 4 oz$71
  • Low-tack masking film and ¼ in tape$81
  • Matte fabric sealer, 4 oz$121

Equipment

  • Starter airbrush set — 0.3 mm dual-action gravity brush, mini compressor, braided hose$1291
  • Cap jig — holds the crown taut while you spray$241

Guide

  • Printed step-by-step guide for this designIncluded1

Trucker · kit for 12 hats

$1,085

$90.42 a hat

Bought separately $1,234 · you save $149

Includes Dual-action gravity-feed airbrush · Quiet compressor with tank and moisture trap · Cap jig and two spare crown forms · Tabletop spray booth with exhaust fan · and 11 more

Every item in this kit · 15 items

Blanks

  • Trucker blank, natural cotton twill front$7812

Stencils

  • Desktop stencil cutter, 12 in — the "stencil printer": cuts mylar from this design's layer files$2991
  • Stencil mylar, 7 mil, 12 × 12 in$2210 sheets
  • This design's layer files, every layer (SVG)Included1

Paint & masks

  • Water-based textile airbrush colour, 4 oz — one per colour in this design$1124 oz × 8
  • Transparent base and reducer, 16 oz$161
  • Low-tack masking film$181 roll
  • Matte fabric sealer, 16 oz$281

Equipment

  • Dual-action gravity-feed airbrush, 0.3 mm$1351
  • Quiet compressor with tank and moisture trap$1791
  • Cap jig and two spare crown forms$641
  • Tabletop spray booth with exhaust fan$1491
  • Cleaning pot, brushes and a half-mask respirator$991
  • Heat gun for curing$351

Guide

  • Printed step-by-step guide for this designIncluded1

Trucker · kit for 12 × 12 hats

$3,165

$21.98 a hat

Bought separately $3,724 · you save $559

Includes Two dual-action gravity-feed airbrushes · Production airbrush · Twin-piston compressor with tank and two regulators · Production spray booth · and 13 more

Every item in this kit · 17 items

Blanks

  • Trucker blank, natural cotton twill front$756144

Stencils

  • Stencil cutter-plotter, 24 in — the production "stencil printer"$6491
  • Stencil mylar, 7 mil, 12 × 12 in$8550 sheets
  • This design's layer files, every layer (SVG)Included1

Paint & masks

  • Water-based textile airbrush colour, 32 oz — one per colour in this design$38432 oz × 8
  • Transparent base and reducer$491 gal
  • Low-tack masking film$543 rolls
  • Matte fabric sealer$891 gal

Equipment

  • Two dual-action gravity-feed airbrushes, 0.3 mm$2702
  • Production airbrush, 0.5 mm, for base fades$951
  • Twin-piston compressor with tank and two regulators$3291
  • Production spray booth, two fans$2891
  • Three cap jigs$1923
  • Cleaning station, respirator and spare cartridges$1391
  • Cap heat press for curing$2791
  • Drying rack, 24 caps$651

Guide

  • Printed step-by-step guide for this designIncluded1

The creator

An illustrated portrait for Sunny (an illustration, not a photograph)

Sunny

@sunny

Strips it fast and stays for the grab.

  • Owyhee PMD Hatch Pale Ale — a river beer by Sunny
  • Owyhee Canyon Mayfly Pale Ale — a river beer by Sunny
  • Riverstone Rust Mayfly Wet Fly — a fly pattern by Sunny

See everything by @sunny