How to Knit a Double-Thick Hat Brim
One technique I developed is to knit a double-thick hat brim. When the weather gets cold and the wind is blustery here in New York and my family and clients appreciate the advantage of a wind-resistant brim. Your ears stay nice and toasty with a double layer of fabric that does not shift around like a fold-up brim is apt to do.
There are different approaches to creating a double-thick brim and my preferred method is, I believe, one of the easiest for knitters of just about any skill level to master. The technique is to knit the hat with about twice the length of brim the pattern calls for, then turn the beginning edge up so it is next to the live stitches. The cast-on edge is joined, one stitch at a time, with the live stitches. After just one round of knitting the brim is double thick and you may complete the hat according to the pattern.
Many existing patterns could be modified to use this technique, or you can try one of the knitting patterns available on in my Ravelry Store:
Guys Winter Hat
There's a YouTube video tutorial on how to do this here, or you can watch right now: