Are you talking about "Athletic Mesh" material. I've seen shirts and hats made with this stuff. What do you mean when you say "poly" on top??? I'd use two layers of cut-a-way backing and maybe even one or two layers of tear-a-way on top. You know, to give the thread something to hold on to. Possibly stopping the machine before the design ends and removing the excess topping possibly before the design does it's outline. That's if there IS an outline. Here's an idea, get some patch material... like the iron on stuff you find for little boy pants knee caps at Wal*Mart, and iron it on to the back of the cap front. We've done that before. You could always tell the customer that the design in question doesn't sew out well on a cap like that because the intricacies in the design cause for problems in holes of the fabric. We've sewn on mesh bags before but it's always been large fonts or big designs with plenty of backing. Ed Ed & Maralien Orantes E.M. Broidery 900 Terry Parkway, Ste. 200 New Orleans, La. 70056 504-EMBROID ery (504-362-7643) -----Original Message----- From: amayausers-bounce@xxxxxxxxxxxxx [mailto:amayausers-bounce@xxxxxxxxxxxxx]On Behalf Of HK Acree Sent: Friday, February 25, 2005 10:00 AM To: amayausers@xxxxxxxxxxxxx Subject: [amayausers] Cap Issue Looking for some ideas for sewing a cap. Would like to include a jpg of the cap to this post but am not sure it is allowed. The cap is an OTTO 23-368, polyester material that has what I can only describe as small vent holes in it. I have a good design, sewed many dozens of a different type cap with it. My issue is the small columns want to try to hide in the vent holes. More column width is not really the answer as this detracts from the way the design looks. Am considering using poly on top to see if I can do better. Has anybody used poly on a cap? Any and all opinions wanted. Herb Royal Embroidery