I was looking to replace the hatband on a straw hat I bought on eBay and came across a few (but not many) hatbands made of paracord.

Survivalists will know that 550 milspec paracord can be used as an emergency rope due to its tensile strength. It seems a whole industry now exists for hobbyists and craftsmen. Because carrying 30 feet of rope can be a bit awkward, folks have taken to making bracelets, rifle slings, and a host of other items. Sadly, not many people make hatbands out of it.

So I thought maybe I'd try my hand at making my own. The stuff isn't expensive, and the only tools one needs pretty much are a good pair of scissors and a butane lighter. There are a number of different weaves or braids, the main one being called the "cobra," which can be learned in seconds. A minute, if you're slow.

My first attempt quickly became my third attempt, as the guide I used suggested adding three inches to the measured length, but it was a good inch to inch-and-a-half too short. I now have the inner strand measured to fit, but find I didn't buy enough cord for the outer layer (the rule of thumb I've read is one foot for every inch measured, which means I need about 26 feet, and I only bought 16. The store is close by, so I should be able to get more tomorrow.

Has anyone here done any work with paracord? Any hints, tips, warnings or ideas?

I'm not interested in turning this into a money-making operation, but I can easily see how it could become one.

Google Stormdrane, he has a blog on all things paracord......

I made a few things several years back. My best was a watch band that I still use.

It took me something like 3 hours.

I enjoyed it, but got busy.

I've done some very simple things by watching YouTube. Pretty fun.

Stormdrane yep. Pair of forceps can come in handy at times.

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Any hints, tips, warnings or ideas?

You have to melt the ends when you are done (or after you cut a section off the main roll), so it doesn't unravel. This melted paracord/nylon attains the temperature of the surface of the sun, and clings viciously to exposed skin (don't ask me how I know). It will hurt for days (remember from Biology class how many ultra-sensitive nerve endings are in your fingers?).

You get used to it.

After I melt the ends for a finished product, I smoosh it down with the flat edge of an old chisel. This keeps it nice and neat/flat. Also, have a good sharp scissors handy. I don't smoke, but on my last deployment, I went through Bic lighters pretty quickly.

Enjoy. It's a great hobby. I've made hat bands, bracelets, key chains, a couple rifle slings, dog collar/leashes, ... It's a great hobby.