Whitewater Cutthroat Trout Trucker Hat

by @john

Out of the rapids, into the cold air.

A cutthroat trout leaping a whitewater stream below snowy slate blue peaks, in golden ochre, coral and river teal, for days on the water.

A cutthroat trout clears a rushing mountain stream, with snowy peaks and pines behind it. The fish is golden ochre and coral orange with a crimson red throat slash, over river teal water and snow white foam.

  • Cutthroat trout mid-leap over whitewater
  • Crimson red throat slash, spotted gold flank
  • Snowcapped slate blue peaks behind pines
  • River teal water breaking around boulders
  • Eleven colour layers, sky to spray

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 cutthroat trout hangs in the air over a fast river, body curved, fins spread. Crimson red marks its throat. Below it the water breaks white over charcoal boulders, and behind it pines climb toward snowcapped slate blue mountains under a pale sky.

Wear it on the bank, at the boat ramp, or in line for coffee after a long morning. The fish faces forward, so people see the red slash and the spotted gold flank first, then the mountains behind.

Crimson red is the colour to get right. Keep it to a narrow slash under the jaw and a touch on the gill plate, and let the coral orange carry the rest of the warmth.

The water it was painted from

The Yellowstone River

Yellowstone RiverParadise Valley, Montana · MT, WY

River
Yellowstone River, Paradise Valley, Montana
States
MT, WY
Fish
Yellowstone cutthroat trout, Brown trout, Rainbow trout
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, slate blue, snow white, pine green, river teal, charcoal, golden ochre, coral orange, crimson red

Details

Subject
cutthroat trout
Style
painterly illustration

Make it yourself

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

AdvancedAbout 5 hours at the bench, plus curing11 layersYou'll need an airbrush, a cap jig and 9 colours

The palette

  • Sky blue
  • Slate blue
  • Snow white
  • Pine green
  • River teal
  • Charcoal
  • Golden ochre
  • Coral orange
  • Crimson red

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. Mountains
  3. Snowcaps
  4. Pines
  5. River
  6. Rocks
  7. Trout body
  8. Flank
  9. Throat slash
  10. Spots
  11. Whitewater

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

  • Slate blue

    White with blue and a touch of black, about 4 : 1 : ½

  • Snow white

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

  • Pine green

    2 parts green, 1 part black, a drop of blue to cool it

  • River teal

    2 parts blue, 1 part green, a touch of white to lift it

  • Charcoal

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

  • Golden ochre

    2 parts yellow, 1 part brown, a drop of black

  • Coral orange

    1 part red to 2 parts yellow

  • Crimson red

    3 parts red, 1 part blue, a drop of black to deepen it

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 soft fade across the top, paling toward the peaks

    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 · Mountains — 0.35 mm · 20–25 PSI

    slate blue — a jagged range sitting behind the tree line

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

    Colour Slate blue — White with blue and a touch of black, about 4 : 1 : ½

    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 · Snowcaps — 0.35 mm · 20–25 PSI

    snow white — snow on the ridges and summits

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

    Colour Snow 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.

  4. 4 · Pines — 0.35 mm · 20–25 PSI

    pine green — dark conifers crowding both banks

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

    Colour Pine green — 2 parts green, 1 part black, a drop of blue to cool 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.

  5. 5 · River — 0.35 mm · 20–25 PSI

    river teal — a stream running down and toward the viewer

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

    Colour River teal — 2 parts blue, 1 part green, a touch of white to lift 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 · Rocks — 0.35 mm · 20–25 PSI

    charcoal — boulders along the banks and in the current

    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.

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

    golden ochre — the fish arched in mid-air over the water

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

    Colour Golden ochre — 2 parts yellow, 1 part brown, a drop of black

    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 · Flank — 0.35 mm · 20–25 PSI

    coral orange — a warm wash along the flank, belly and fins

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

    Colour Coral orange — 1 part red to 2 parts yellow

    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 · Throat slash — 0.35 mm · 20–25 PSI

    crimson red — the slash under the jaw and the gill plate

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

    Colour Crimson red — 3 parts red, 1 part blue, a drop of black to deepen 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.

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

    charcoal — scattered spots thickening toward the tail

    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 · Whitewater — 0.2–0.3 mm · 12–15 PSI

    snow white — foam, spray and riffle lines around the rocks and under the fish

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

    Colour Snow 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 full panel outline and spray sky blue as a soft fade from the top edge down. Starting point: 20 PSI, 0.3 mm needle, 15 cm distance.

  2. Lay the mountain mask and spray slate blue for the range, darker at the base. Starting point: 20 PSI, 0.3 mm needle, 10 cm.

  3. Use the snowcap mask and mist snow white along ridges and summits, leaving blue showing in the gullies. Starting point: 18 PSI, 0.2 mm needle, 8 cm.

  4. Mask both banks and spray pine green for the conifers, building tree tips with short passes. Starting point: 22 PSI, 0.3 mm needle, 8 cm.

  5. Lay the river mask and spray river teal, deeper in the middle and lighter toward the edges. Starting point: 20 PSI, 0.3 mm needle, 12 cm.

  6. Use the rock mask and spray charcoal for boulders on the banks and in the current. Starting point: 20 PSI, 0.3 mm needle, 8 cm.

  7. Mask the trout silhouette and fill it with golden ochre, a little heavier along the back. Starting point: 20 PSI, 0.3 mm needle, 8 cm.

  8. With the trout mask still down, fade coral orange along the flank, belly and fins. Starting point: 18 PSI, 0.2 mm needle, 6 cm.

  9. Lay the throat mask and spray crimson red for the slash and gill plate in thin coats. Starting point: 15 PSI, 0.2 mm needle, 5 cm.

  10. Use the spot mask and dot charcoal across the body, denser toward the tail. Starting point: 15 PSI, 0.2 mm needle, 4 cm.

  11. Spray snow white foam and spray around the rocks and under the fish, freehand flicks over the whitewater mask. Starting point: 18 PSI, 0.2 mm needle, 6 cm.

  12. Let the paint cure 24 hours, heat-set if your paint calls for it, then mist two light coats of matte sealer. These settings are a starting point; test on scrap first.

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

  • Flooding the spots so they blur into blobs. Drop pressure and spray short bursts from close in.
  • Letting coral orange cover the whole fish. Keep golden ochre showing along the back so the body has depth.
  • Lifting masks before paint sets, which drags colour. Wait until each coat is dry to the touch.
  • Sealing too heavily and dulling the whitewater. Use two light coats instead of one wet one.

Tips

  • Keep the sky fade light near the peaks so the snowcaps read clearly against it.
  • Spray the river teal in curved passes that follow the current; the water looks like it moves.
  • Let each layer dry to the touch before laying the next mask to keep edges crisp.
  • Test the crimson red on scrap first; a little goes a long way on the throat.
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 John (an illustration, not a photograph)

John

@john

Tight line, quiet feet, zero slack.

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See everything by @john