This message was posted by Steve I on AmayaUsers.com. PLEASE DO NOT REPLY VIA EMAIL. Instead, respond to the thread on the WEBSITE by clicking here: http://www.amayausers.com/boards/ultimatebb.php?/topic/2/842.html#000003 When I do puff hats I usually use two layers of 2mm foam. Any stitching over the foam I use the standard setting for the actifeed and set it anywhere from 27-32, this allows enough thread as to not crush the foam and loose the effect. It took a lot of sew outs and tinkering to get the process fine tuned. I went to the mall and looked at caps to see how they were done, how they handled corners and which ends were capped and which were not. It helps to use foam as close as possible to the thread color. I found all colors at Michaels. I have also found that the foam with the adhesive back tears off cleaner than the foam without. Steve I. Trinity Embroidery =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================