Welding Cap Size, Depth & Brim Info
How to Measure
Use the image below as a guide:
- Green line: Size (inches around)
- Blue line: Depth (inches, one side only)
- Pink line: Brim length (in inches)
Hat Size Measurements
| Hat Size | Band Measurement |
|---|---|
| 7 | 22 ⅛" |
| 7 ⅛ | 22 ½" |
| 7 ¼ | 23" |
| 7 ⅜ | 23 ⅜" |
| 7 ½ | 23 ¾" |
| 7 ⅝ | 24" |
| 7 ¾ | 24 ¼" |
| 7 ⅞ | 25" |
These are the finished measurements of the hat band. Cotton fabrics have a bit of natural stretch that varies slightly between fabrics.
If you’re between sizes, choose the one closest to your actual head measurement.
Custom sizes are available to the nearest ⅛" (for size) and ¼" increments for depth and brim. Add your custom request in the text box on the product page.
Hat Depth Options
At HD Welding Hats, “depth” replaces old terms like high crown or low crown. It simply means how far the cap comes down at your ear — a mix of skull shape and personal preference.
| Depth | Description |
|---|---|
| 6" | Shortest depth, measured from top center (TDC) to band edge at ear. Available by request only; not for Pipeliner Fancy caps or styles with sweatbands. |
| 6 ½" | “Short crown.” Usually meets the top edge of the ear. |
| 7" | Mid-depth — our most popular fit. Falls between short and high crown. |
| 7 ½" | “High crown.” Typically covers the top half of the ear. |
| 8" | Longest depth, ideal for sizes 7 ⅝ and larger, or anyone who prefers more coverage. |
Everyone’s fit preference is different — there’s no right or wrong choice.
Brim Length Options
| Brim Length | Description |
|---|---|
| 2" | Shortest brim. Great for smaller sizes, shorter necks, or minimal obstruction. |
| 2 ½" | Standard brim — a balanced choice that works for most welders. |
| 3" | Longer brim for added coverage of ear and neck, without getting in the way. |