I made up my mind im going to redo the whole headband part and leave all the other stuff alone. Do you think there is a sewingsite out there somewhere? Hahaha!
There are these things made out of paper called books. You can find them in fabric stores.
The leather will be too heavy for a sewing machine. Even my old treadle couldn't sew the leather. Sew, (pun) I would suggest going to a craft, fabric or maybe an outdoor store and purchasing an awl, or ready stitcher or some sort of name like that. It will come with a thick, waxed thread which is almost string like, a bobbin, and needle. It will have a wooden handle on it where the bobbin goes in. You thread it, push the needle through the leather, grab the thread and pull it through, and then repeat and do a knot, which is sure to be somewhere on the internet. Repeat. I've got an old pack that I made and that stitching is still holding up well. If your fingers get sore or can't pull the thread, a pair of needle nose pliars will do the trick.
Note: If you are planning on wearing this hat to work, it most likely will not meet the ANSI and OSHA and whatever else your state has. You might get a fine. But, it will be fine to wear at a GTG or put "on display".
Smokejumpers know how to sew. If you need new strap material, I ordered it from The Rainshed in Corvallis, OR. They are on the internet, and have mass quantities of outdoor fabrics, fleece, straps and hardware.
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