I just posted a tutorial & free pattern for a welders cap. I didn't get to take pics of me making one, but I do have text instructions. Feel free to email me with any questions. (my email is on my blog)I am backed up with orders right now, but I will make one and take pics asap to make it easier to follow, but it's super simple
http://wildflowersandwhimsy.blogspot.com/2011/03/welders-cap-tutorial-pattern-download.html