I will be putting my cap design on Patreon when I ink it up better and scan it.
My first step was looking at original caps, lots of original caps, and deciding which styles fit my 1830s goal. Then I drew out the foundation shapes on paper and did a paper fitting. Folding, trimming, slashing, until I was happy with the fit and shape. The paper plan became a muslin mock-up. Keeping in mind the heavier drape to muslin, this was a check for how well it fit my head. I was pleased with the fit. I only altered the cheek area to be more rounded.I transferred the finished design to paper by hand, adding assembly notes. (Then, I wrote up a couple variations.)One of the nice things about working with sheer fabric for smaller projects is the pattern can go underneath and be traced through the fabric.The foundation is 3 pieces cut out.Each piece got a rolled hem. The back piece has a quarter inch hem on the bottom side. The crown (not pictured) has a rolled gather all the way around. The rolled hems were whipped together.
The ruffles are each double the length of the placement (brim edge, neck edge, crown.) I used a rolled hem along each side, tapering for the neck edge and crown. My rolled hem is not as fine as I would like. Muscle memory is challenged going from the type of sewing used for straw to the type of sewing used for sheer fabrics. The front ruffle and crown ruffle are both tapered doubles, while the neck ruffle is single. Clara for model.
If I Had My Own Blue Box: 
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