The Ray-Way Insulated Hat Kit is a kit that you sew together yourself. The hat is ultra-light and compact - the size medium weighs only 1.1 ounces - and occupies very little space in a backpack or clothing bag.

The Insulated Hat consists of one layer of Alpine 3D insulation, which is about 0.9" thick. This insulation is sandwiched between two layers of lightweight nylon fabric. And because the inner and outer layers are both the same size, the hat is fully reversible.

The Ray-Way Insulated Hat is intended for use with a quilt or sleeping bag, as well as outdoor activities such as camping and hiking in cool to cold weather.

The hat is very breathable, allowing normal insensible perspiration to evaporate. In this way it offers maximum warmth. It is not intended as a rain hat, but of course may be worn beneath an umbrella or the inside hood of a rain parka.

Determining hat size

Measure the circumference of the head, (distance around) to the nearest inch. To do this, position a soft measuring tape, or a length of string, about a finger's width above the eyebrows. If using a string, transfer it to a yardstick for reading.

The Kit contains complete, step-by-step sewing instructions, written and illustrated by Ray & Jenny.

The Ray-Way Insulated Hat Kit contains lightweight nylon fabric in two colors, one layer of synthetic insulation, chin strap, micro cordlock, pattern and detailed sewing instructions.

Note: effective June 2005 we changed the design of the Insulated Hat Kit to make the seams more robust. The change was reflected in our sewing instructions. But if you purchased your Insulated Hat Kit before that date, we recommend you not launder the hat in a washing machine, which in rare cases could damage the simple seams. Instead, hand-wash the hat in a basin of warm water with mild soap, rinse thoroughly and allow to air dry. With proper care even these simple seams should give a lifetime of good service. Our updated Insulated Hat Kit uses much more robust seams, and when laundering it is safe to use the gentle cycle on your home washing machine.

"I think the Insulated Hat is your most under-stated item. It seems so mundane on the web page whereas the backpack, tarp, quilt etc. all shout for themselves. But the times I've used the insulated hat in a challenging cold/wet/windy situation and it's turned the whole thing around in a matter of minutes. Both night and day, it offers amazing utility for a 1oz weight. I never go camping without one." -Mike G.