http://www.craftstylish.com/item/...
Thank you for this link, I also want to try hats without the cap hoop!
Try emblibrary at http://www.emblibrary.com/EL/elpr...;CS_Catalog=Elprojects
I have embroidered on a cap by first hooping the stabilizer (tear away or cut away) and then pinning the hat to the stabilizer. You could also use a basting stitch to hook the hat to the stabilizer. I was able to hold enough of the hat down so that it was reasonably flat around the area of the embroidery. I had to adjust the height of the foot to clear the extra thickness of the hat.
ehow.com has some instructions for a single needle machine. If you need instructions for a 6-needle with cap hoop, PM me and I will send them to you.
Good luck! :)
Marion in KY