How to make a cotton cap for under a helmet...

[Abby'sMom]

Hi Amanda!

I decided to put these directions in a new thread just in case someone else was interested. As I mentioned in the other thread, the cap has significantly reduced sweat and nearly eliminated odor under the helmet. It's a great barrier between sensitive skin and the plastic/foam in the helmet and it wicks moisture away from the scalp.

This is an easy project that does not involve any sewing. I've found Gerber caps work best but there may be another brand out there that will do the trick as long as it's 100% cotton. If you have any questions just let me know!

Here is what the Gerber caps I use look like to start...

First remove the stitches holding the folded rim. There are two spots (one on each side) that need to be removed. I use a small pair of scissors used for removing sutures but a seam ripper or other very tiny pair of scissors will work. Be careful to snip only the thread holding the rim up and not the cap itself...

This is what the cap looks like after the rim is unfolded...

Next pull the inner layer away from the outer layer of the cap and cut off the Gerber tag. This will make a small hole that gives you access to the only other place where the outer part of the cap is connected to the inner part (the very top of the cap)...

Now pull the cap partially inside out and snip the threads connecting the two layers...

Once all the stiches are removed you'll be left with what looks like a small oval pillow (yet to be stuffed) with a hole at one end where the tag was removed. Cut the end with the hole off (straight across). I drew a line with a marker so you can see what I mean...

Next cut as shown in the picture below so that the cap will go around the face. Every child's head and face is a little different size and shape so this cut has to be custom fit to your child. My advice is to cut a small section then try the cap on to see if it fits. If the face opening needs to be larger, take the cap off, trim it some more and try it on again. Do this until it fits the way you like. It's better to be conservative with your cutting at this point and need to trim it a little than to make a big cut to start with and find you've cut off too much...

Once the opening for the face fits the way you like you need to mark the location of the ear slits. If your orthotist used a computer laser scan to fit your child's helmet then you probably saw this done. Use a highlighter (just because it won't show as much) to put a dot at the top and bottom of each ear...

Remove the cap and cut a slit connecting the two dots on each side. Just cut a straight line. If you try to cut a circle the opening will be to wide. Put the cap back on to make sure the openings are in the right place...

At this point I also trim around the bottom of the cap so that approximately 1 inch of material sticks out from the bottom of the helmet. I also round out the side burns. Abby has two strips of Velcro on either side of her helmet so I attach the edges of the cap around her face to them. The cotton sticks well to Velcro. This keeps the cap from slipping down over her eyes. A piece of Velcro at the bottom of the helmet in the back also prevents slipping. Your orthotist may give you a piece to use or you can find some in the craft department of most dept. stores.

Here's a picture of the finished product...no more smelly head or irritated skin!

[Kaitlynn's Mommy]

Thanks so much!!! :) I'm going to have to pick some of them up!!! :)

[amizzle]

Mandy!

Thank you so much for the wonderful directions for the cap. You must be pretty crafty (got any others you want to share?) I will definitely be making a trip to walmart tomorrow to get one for carson.

p.s. love seeing your avatar pic (and everyone else's) You are BEAUTIFUL.

[Janet]

Mandy....thanks for sharing, I know it will help out a lot of other families.

[Tyler&Jakobsmommy]

Hey where were you when my kids had their stinky helmets??? Does this work with all kinds of helmets or just the clear plastic one like Abbys and Carsons? Also I wanted to add if you don't already have air holes drilled in your helmet ask it for some makes alot of difference.

[Abby'sMom]

Originally Posted by Tyler&Jakobsmommy

Hey where were you when my kids had their stinky helmets??? Does this work with all kinds of helmets or just the clear plastic one like Abbys and Carsons? Also I wanted to add if you don't already have air holes drilled in your helmet ask it for some makes alot of difference.

They say necessity is the mother of invention and in this case contact dermatitis called for the invention of a mother!

When I first came up with the cap idea it was intended to be temporary to protect Abby's irritated skin...discovering that it reduced sweat and odor was an accidental discovery and a pleasant surprise!

Good point about the air holes...Fortunately Abby's clear helmet came with them. I think the caps could probably work under any helmet. I would love some feedback if someone wants to give it a try.

[Pocket]

We are not using helmet therapy but I thought I would check out this thread anyway - it's such a great idea - maybe you could make and market something for this specialised niche in the market sell it on ebay??- or perhaps make it a sticky at the top of the helmet thread coz it's sure to be of use to everyone whose child is having helmet therapy.

[Abby'sMom]

Originally Posted by Pocket

We are not using helmet therapy but I thought I would check out this thread anyway - it's such a great idea - maybe you could make and market something for this specialised niche in the market sell it on ebay??- or perhaps make it a sticky at the top of the helmet thread coz it's sure to be of use to everyone whose child is having helmet therapy.

Thank you for the positive feedback and the great suggestions! Our orthotist also suggested I sell the caps but because they need to be custom cut I didn't think it would work...plus I like being able to share an idea that may make someone's child more comfortable.

I'm going to take your advice and see if the thread can be made a sticky. That way new members and visitors won't miss out on the idea.

I think I'll try to contact Gerber and see if they are willing to sell the caps before they have been completely assembled...that would save several steps in the process!

Thanks again!

[amizzle]

Made Carson a cap today, laptop in one hand scissors in the other!

He wore it all day!

I'll try and post a picture soon.

Thanks Mandy!!!!

[Abby'sMom]

Originally Posted by amizzle

Made Carson a cap today, laptop in one hand scissors in the other!

He wore it all day!

I'll try and post a picture soon.

Thanks Mandy!!!!

Looking forward to the picture and your feedback as well!

I forgot to mention that when Abby takes her daily helmet break I wash the cap by hand using her baby shampoo then tumble dry it with other clothes. I have two or three caps on active duty at any given time so that I don't have to run the dryer just for a cap. I've tried air drying it but it leaves the cap a little stiff.