Jade Water Stonefly Trucker Hat

by @dekasso

Down where the light breaks into pieces.

A realistic stonefly nymph on amber river stones under green, sunlit water, for anglers who fish below the surface.

A stonefly nymph crawls across a sunlit river stone, legs spread and antennae reaching. The scene is coloured in moss green, umber and amber, with pale gold light slanting through the water.

  • Stonefly nymph on sunlit river stones
  • Pale gold rays through green water
  • Amber banding on a sepia body
  • Moss green, umber and cream palette

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 stonefly nymph grips a rounded stone, six legs braced and antennae stretched toward the current. Pale gold shafts cut through green water from above. Umber and amber stones crowd the bottom, flecked with moss.

Wear it on the walk to the riffle or in line for coffee after. Anglers will clock the bug first. Everyone else sees warm stones and green light.

Light shafts carry the whole piece. Mask them as long, narrow wedges and keep the pale gold soft at the edges, so the rays read as water and not stripes.

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
deep forest green, moss green, pale gold, umber, amber, sepia, cream

Details

Subject
stonefly nymph
Style
realistic underwater scene

Make it yourself

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

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

The palette

  • Deep forest green
  • Moss green
  • Pale gold
  • Umber
  • Amber
  • Sepia
  • Cream

The layers

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

  1. Deep water
  2. Water glow
  3. Light shafts
  4. Stones
  5. Warm stone tops
  6. Algae
  7. Stonefly
  8. Segments
  9. Glints

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

  • Deep forest green

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

  • Moss green

    2 parts yellow, 1 part green, a drop of black to deaden it

  • Pale gold

    3 parts yellow, 1 part brown, a touch of white so it stays opaque

  • Umber

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

  • Amber

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

  • Sepia

    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

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 · Deep water — 0.5 mm · 25–30 PSI

    deep forest green — a dark fade around the edges and along the bottom

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

    Colour Deep forest green — 2 parts green, 1 part black, a drop of blue to cool 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. 2 · Water glow — 0.35 mm · 20–25 PSI

    moss green — a soft green haze across the upper half

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

    Colour Moss green — 2 parts yellow, 1 part green, a drop of black to deaden 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.

  3. 3 · Light shafts — 0.35 mm · 20–25 PSI

    pale gold — slanted rays falling from the upper left

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

    Colour Pale gold — 3 parts yellow, 1 part brown, a touch of white so it stays opaque

    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 · Stones — 0.35 mm · 20–25 PSI

    umber — rounded river stones filling the lower half

    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.

  5. 5 · Warm stone tops — 0.35 mm · 20–25 PSI

    amber — sunlit crowns on the stones

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

    Colour Amber — 3 parts yellow, 1 part red, 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.

  6. 6 · Algae — 0.35 mm · 20–25 PSI

    moss green — green tufts and pebbles between the stones

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

    Colour Moss green — 2 parts yellow, 1 part green, a drop of black to deaden 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.

  7. 7 · Stonefly — 0.35 mm · 20–25 PSI

    sepia — body, six legs, long antennae and twin tails

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

    Colour Sepia — 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.

  8. 8 · Segments — 0.3 mm · 18–22 PSI

    amber — banding on the abdomen, wing pads and leg joints

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

    Colour Amber — 3 parts yellow, 1 part red, a drop of black to deepen 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.

  9. 9 · Glints — 0.2–0.3 mm · 12–15 PSI

    cream — sparkles on the stones and along the insect's back

    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

  1. Mask the outer panel edge. Spray deep forest green around the edges and bottom at about 20 PSI, 0.3 mm needle, 15 cm away. These settings are a starting point; adjust to your paint.

  2. Fade moss green across the upper half at about 18 PSI, 0.3 mm needle, 12 cm, blending into the dark edges.

  3. Lay wedge-shaped masks from the upper left. Mist pale gold at about 15 PSI, 0.3 mm needle, 10 cm, heaviest near the top. Lift the masks while damp-dry.

  4. Cut a stone-shape stencil. Spray umber stones across the lower half at about 18 PSI, 0.3 mm needle, 8 cm, darker underneath each one.

  5. Shift the same stencil slightly up. Spray amber on the stone tops at about 15 PSI, 0.2 mm needle, 6 cm.

  6. Freehand moss green tufts and small pebbles between the stones at about 15 PSI, 0.2 mm needle, 5 cm.

  7. Place the stonefly silhouette stencil on the central stone. Spray sepia for body, legs, antennae and tails at about 18 PSI, 0.2 mm needle, 6 cm.

  8. Use a segment stencil over the body. Spray amber bands on the abdomen, wing pads and leg joints at about 12 PSI, 0.2 mm needle, 4 cm.

  9. Hit cream glints on stones and along the insect's back at about 12 PSI, 0.2 mm needle, 3 cm, in short taps.

  10. Let the piece dry fully, then heat-set and seal following your paint maker's directions 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

  • Rays that look like stripes: soften mask edges and back off to 10 cm for a feathered fade.
  • Muddy stones: let umber dry before adding amber, or the two will blend into brown.
  • Fuzzy antennae from overspray: drop pressure and move in closer for fine lines.

Tips

  • Spray a quick test card of each colour first to check flow and opacity.
  • Keep the legs crisp: press the stencil flat and spray at a slight angle away from thin parts.
  • Build the pale gold rays in two light passes rather than one heavy one.
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

  • 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 Dekasso (an illustration, not a photograph)

Dekasso

@dekasso

Wherever the truck rolls to a stop.

  • Tidewater Sundown Pale Ale — a river beer by Dekasso
  • Prairie Wildflower Portrait Trucker Hat — a trucker hat by Dekasso
  • Ember Golden Stonefly Nymph — a fly pattern by Dekasso

See everything by @dekasso