A DIY Sun-Protective Brim for a Bicycle Helmet

INTRO - My girlfriend and I are doing a shakedown cycle tour in prep for our impending two-year bike tour from Vietnam to Mexico [via SE Asia, China, Kazakhstan, Europe, Quebec, and the US] starting in Feb next year.

At the moment we're heading south down the east coast of Australia (from Cairns to Sydney ) and damn the sun is relentless...

Anyway, since I really like my funky new bike helmet but it provides no shade for my face or neck, I've adapted an eleven dollar white canvas cricket hat to the task.

What you'll need...

cloth hat
sewing machine / #10 hand sewing needle
pencil / chalk
thread
scissors
scalpel
cutting board
beer...

The pictures should express most of it really, but here goes -

Find a suitable candidate. White to reflect the sun, canvas to breathe, and CHEAP.

Cut the crown off - to minimise discomfort and maximise ventilation. I cut less off the back to cover the big gap. The front is about 30mm high, and the back is roughly 80mm...

Mark the slots for the chin-strap, and cut out with the scalpel. It's easy to cut more out later, but harder to fix if you remove too much too early... I cut the slots about 4mm wide and 120mm long

Check that it all fits before you finish it...

Bind the edges. With a sewing machine, or by hand, zig-zag or blanket-stitch over the cut edges to keep the fabric from fraying. Reinforce the sliced-through vertical seams by sewing back-and-forth a bit.

Now whack it on ya noggin and get cyclin', safe from the sun.