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Spokes & Stitches

Bluster Buster Cap Sewing Pattern & Instructions

Bluster Buster Cap Sewing Pattern & Instructions

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The Bluster Buster Cap is a close-fitting skullcap designed to fit under a bicycle helmet. The cap provides additional warmth and wind protection for winter cycling, as well as for other sports that require a helmet. The cap has a narrow visor at the front and an extended back ear flap panel that covers the back of the neck and ears.

The cap is fully lined, and elastic is inserted into the center back band seam for greater size adjustability.

Recommended fabrics:

The Bluster Buster Cap is constructed from three different fabrics:

The body of the cap should be made in a firm midweight to heavyweight woven.

Midweight wovens are also recommended for the cap lining.

The ear flap lining can be made of a soft, warm fabric with a mid to high pile, such as fleece or flannel.

Additional notions:

midweight fusible interfacing to block-fuse the body fabric

heavyweight nonwoven fusible interfacing for the cap visor

one small piece of elastic for adjustability in the back of the cap

This PDF pattern is designed to be printed at home or at a third-party copyshop. Your download will contain 3 files:




When printing the pattern files, be sure to print at actual size (100%) or select “do not scale” on your print screen. Use the 2” (5 cm) test square to check that your file has printed at the correct size. Scaling the pattern up or down from its intended size may result in the pattern pieces not fitting together properly.

All pattern files contain separate layers for each size, which can be turned off or on according to the sizes which you would like to print. Please note that this feature only works in Acrobat Reader. You can download Acrobat Reader software for free at this link:

The large format/A0 files have also been optimized for use with a projector.

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