Banded Wing Caddis Trucker Hat

Wings folded, waiting out the riffle.

A banded-wing caddis resting on wet river stones, in sage green, umber and ochre over an olive haze, for days spent on moving water.

An adult caddisfly rests on a bed of wet river stones, wings folded like a tent and antennae swept forward. It is coloured in sage green and umber bands over ochre legs, with slate stones and an olive haze behind.

Adult caddis with tented, banded wings
Sage green wings barred in umber
Resting on wet slate river stones
Long ochre antennae and jointed legs
Soft olive haze behind the insect

The cap

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

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
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
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
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

Cap	Profile	Crown height	Visor	Adjusts to
Trucker	Mid profile	3½ in (8.9 cm)	Pre-curved, 2¾ in (7 cm)	21½–24 in (54.5–61 cm)
Rope cap	Mid-high profile	4 in (10.2 cm)	Near-flat, 2⅞ in (7.3 cm), contrast rope	21½–23¾ in (54.5–60.5 cm)
Dad hat	Low profile	3¼ in (8.3 cm)	Curved, 2¾ in (7 cm)	21–23½ in (53.5–59.5 cm)
Five-panel camp	Low profile	3¼ 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.

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.
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 caddis sits low on the stones, wings pulled into a long peaked roof. Dark umber bars cross the pale sage veins. Two thin antennae reach forward, and the stones under its feet still shine wet.

It wears well on a gravel bar at dusk, when the real ones start fluttering over the water. Anglers will spot the folded wing from across the parking pull-out and know exactly what it is.

Cream highlights do the heavy lifting here. A few thin lines along the wing veins and one dot in the eye turn a flat shape into an insect that looks ready to lift off.

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: olive haze, slate, umber, cream, sage green, ochre, black

Details

Category: Adult Caddis
Subject: caddisfly
Style: realistic illustration

Make it yourself

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

AdvancedAbout 4½ hours at the bench, plus curing9 layersYou'll need an airbrush, a cap jig and 7 colours

The palette

Olive haze
Slate
Umber
Cream
Sage green
Ochre
Black

The layers

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

Haze
Stones
Stone shadows
Stone glints
Wing base
Wing bands
Body and legs
Detail
Highlight

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

Olive haze
2 parts yellow, 1 part black, a drop of red to warm it
Slate
White with blue and a touch of black, about 4 : 1 : ½
Umber
Equal parts red, yellow and blue, then a drop of black to deepen it; or burnt umber straight from the bottle
Cream
White with a drop of yellow and the smallest touch of brown
Sage green
2 parts green, 1 part white, a drop of black to dull it
Ochre
2 parts yellow, 1 part brown, a drop of black
Black
Black from the bottle, sprayed in light passes; a heavy coat bleeds

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 · Haze — 0.5 mm · 25–30 PSI
olive haze — a soft fade behind the insect that thins out toward the edges
Mask None on the panel itself: the mesh and the visor are already masked from the prep.
Colour Olive haze — 2 parts yellow, 1 part black, a drop of red to warm it
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 · Stones — 0.35 mm · 20–25 PSI
slate — a bed of rounded river stones along the bottom of the scene
Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.
Colour Slate — 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 · Stone shadows — 0.35 mm · 20–25 PSI
umber — dark gaps and undersides between the stones
Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.
Colour Umber — 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.
4 · Stone glints — 0.35 mm · 20–25 PSI
cream — wet light on the tops of the stones
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.
5 · Wing base — 0.35 mm · 20–25 PSI
sage green — the long tented wing laid over the body
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 · Wing bands — 0.35 mm · 20–25 PSI
umber — dark bars and mottling across the wing
Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.
Colour Umber — 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.
7 · Body and legs — 0.35 mm · 20–25 PSI
ochre — the body, jointed legs and two long antennae
Mask Lay this layer's mylar stencil and burnish the edges flat with your thumbnail.
Colour Ochre — 2 parts yellow, 1 part brown, a drop of black
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.
8 · Detail — 0.3 mm · 18–22 PSI
black — the eye, wing veins and leg joints
Mask The hand-cut subject stencil, inner pieces first, then the outline piece.
Colour Black — Black from the bottle, sprayed in light passes; a heavy coat bleeds
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.
9 · Highlight — 0.2–0.3 mm · 12–15 PSI
cream — glints along the veins, the wing edge and the eye
Mask None: freehand, with a shield card held against any hard edge.
Colour Cream — White with a drop of yellow and the smallest touch of brown
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

Mask everything but a loose oval for the haze. Spray olive haze at about 18 PSI, 0.3 mm needle, 15 cm away, building light passes so the edges fade out. Treat all settings here as a starting point.
Lay the stone mask along the bottom. Spray slate at 20 PSI, 0.3 mm needle, about 10 cm, filling each rounded stone evenly.
Keep the stone mask on and add umber into the gaps and undersides at 15 PSI, 0.2 mm needle, 5 cm, for soft shadow.
Lift the stone mask. Mist cream on the stone tops at 12 PSI, 0.2 mm needle, 4 cm, in small strokes for wet glints.
Place the wing mask. Spray sage green at 18 PSI, 0.3 mm needle, 8 cm, in two thin coats.
Add the band stencil over the wing. Spray umber at 15 PSI, 0.2 mm needle, 5 cm, pressing the stencil flat so the bars stay crisp.
Mask the body, legs and antennae. Spray ochre at 15 PSI, 0.2 mm needle, 5 cm, keeping the antennae lines thin and even.
Use the detail stencil for the eye, veins and leg joints. Spray black at 12 PSI, 0.2 mm needle, 3 cm, in short controlled bursts.
Finish with cream on the vein lines, wing edge and eye at 10 PSI, 0.2 mm needle, 3 cm.
Let the paint dry for at least 24 hours, then heat-set following your paint maker's directions.
Seal with a thin fabric-safe clear coat and let it cure fully before wearing.

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

Spraying the umber bands too heavy, which bleeds under the stencil. Use thin passes at low pressure.
Fat antennae from spraying too far away. Move in close and drop the pressure.
Skipping the dry time before heat-setting, which smears the fine black detail. Wait the full day.
Over-filling the stones with cream so they look snowy. Keep glints to the tops only.

Tips

Test each colour on scrap fabric first so you can see how the sage green sits over the olive haze.
Keep the haze very light; it should frame the insect, not compete with it.
Weight the antennae stencil flat with a fingertip so the lines stay hair-thin.
Leave a little slate showing between cream glints so the stones read as wet, not white.

An airbrush, compressor, moisture trap, six colour bottles and a cleaning pot. — The kit

Every kit size

Trucker · kit for 1 hat

$224

Bought separately $249 · you save $25

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 — 9 layers$181

Paint & masks

Water-based textile airbrush colour, 2 oz — one per colour in this design$422 oz × 7
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

$1,073

$89.42 a hat

Bought separately $1,220 · you save $147

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$984 oz × 7
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

$3,124

$21.69 a hat

Bought separately $3,676 · you save $552

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$33632 oz × 7
Transparent base and reducer$491 gal
Low-tack masking film$543 rolls
Matte fabric sealer$891 gal

Equipment