Date: April 16, 2004

Product Description
The OR Saraha Cap and skirt are made of SolarLite, a lightweight nylon fabric that is breathable and very UV resistant.  The cap by itself is the OR Taklamakan Cap, a lightweight high ventilation cap for aerobic activities. It has mesh side panels for extra ventilation. The large contoured skirt attaches to 2 snaps on the bill. When attached, the skirt wraps around the mesh sides, but it can also be pulled down to expose the mesh panels for added ventilation if needed. Features summary of the Sahara Cap: SolarLite sun protection fabric, mesh side panels for ventilation, removable sun skirt, foldable foam bill (the cap floats!), cinch-strap rear size adjustment, 5-panel construction, and a drawcord adjustment on the skirt. This 2.7oz/77 g cap has a lot of features!

Initial Report
Product Arrival—The Sahara Cap arrived via UPS in a tough plastic envelope. The cap itself was not enclosed in any packaging. Tags attached to the cap provide a concise description of the cap’s features and sun protection properties of the SolarLite fabric. Overall the packaging and documentation is sufficient and avoids wasting resources.

Quality, Construction, Features, and Fit—I was immediately impressed with the quality of the cap, both in its design and its construction. The quality is superb.  I can readily understand why this cap sells for $37! The fit is excellent and right on target for size Large.

Cap: The cap’s construction is quite complex; it has many different components and panels, and requires a lot of sewing to assemble it. The bill is foam covered with the SolarLite material. Eleven parallel rows of stitching provide shape retention. The bill is black on the edges and underside to minimize reflected light. The top consists of 5 panels sewn together. The 2 side panels are mesh (3 in/8 cm high) and the 3 top panels are contoured SolarLite material. The sweatband is made of a soft absorbent material. The cap is easy to adjust while on using a webbing cinch strap, D-ring and hook and loop closure on the back.

Skirt: The skirt consists of 3 panels with complex contours to completely surround the head. The top hem has elastic in the back center. The center panel on the back of the skirt has ventilation openings in the seams on both sides. There is a black seam binding around all the raw edges. The front of the skirt has an attached drawcord and cord lock to secure it under the chin for windy conditions.

Measurements: The cap’s bill is 3 in/8 cm long at the center. The skirt is 11in/28 cm long in the back and 12 in/30 cm on the sides.

Washing Instructions: “Machine wash cold separately. Do not bleach. Do not use fabric softener. Warm iron. Tumble dry warm.”

Comments—The elastic in the top hem of the skirt (back center) is too tight and puts pressure on the back of my head when I pull the skirt down to expose the mesh panels on the side of the cap. The locations of the snaps on the bill are uneven; one is .25 in/6 mm forward of the other.
 
Test Plan
Test Locations and Conditions—I will test the Sahara Cap in a variety of terrains and climates. In the spring I will do numerous trips in the canyon country of Arizona, Utah, and New Mexico. During the latter part of the test I will do numerous trips in the high mountains of Colorado. The testing environments will consist of: Sonoran desert, desert brushlands, badlands desert, canyon country, pine forest, montane forest, and high elevation alpine country. Expected climatic and weather conditions include: dry and arid, intense sun, strong winds, dust storms, heavy rain, snow, low temperatures, high temperatures, and high elevations with intense UV radiation.

How the Cap Will Be Used—The OR Sahara Cap will be tested in a variety of outdoor activities, including day hiking, backpacking, fishing, canoeing, and yard work. I will wear it with and without the skirt. Testing will be conducted under normal use, using appropriate care to avoid abuse. This will not be a test to challenge the product to see if I can make it fail.

Fundamental Questions—The basic questions to be answered in this test are: 1) How well does the Sahara Cap provide sun protection, with and without the skirt? 2) How comfortable is it (especially carrying a pack uphill in full sun and warm temperatures)? 3) How does it perform in terms of features, adjustability, and versatility in different outdoor situations? And 4) How durable is it?

Observations and Data—This test will be mostly subjective, and performance will be measured in terms of sun protection, personal comfort, versatility, and durability. My goal is to test the Sahara Cap in a wide variety of weather conditions, climates, and terrains. I will carry a notebook on my trips and record my observations while I am in the field, then transcribe them into a trip report when I get home. I will also take a thermometer with me to record the actual temperatures. Data I will record daily are: 1) how the Cap was worn throughout the day, 2) my exertion levels, 3) temperatures, 4) estimated wind speed, 5) estimated humidity, 6) altitude, 7) precipitation (including what form), and 8) my comfort level (on a scale of 0-10). Recording these data on a daily basis and then writing a trip report will ensure that my evaluations are accurate and consistent.

Factors Evaluated—The specific factors to be evaluated in the field tests are as follows:

• Performance: How comfortable is it to wear at different temperatures, exertion levels and in varying weather conditions? How well do the mesh sides work to provide ventilation and keep my head cool, with and without the skirt? How insulating is it in cool weather? How well does the Cap stay on in the wind? Does the skirt stay in place in the wind? How does it do in the rain?

• Versatility: How well does it function in a variety of outdoor activities?

• Ultralight Use: Does the Sahara Cap have a good balance between durability, functionality, and lightweight? Is it as light as it can be, or are there ways it could shed a little more weight without sacrificing comfort or performance (e.g., changing the materials used, dimensions or shape)?

• Usability: When it gets wet, how long does it take to dry out? How compact does it pack? How easy is it to adjust? How well does it fit over a thin microfleece cap or helmet liner? How easily can the skirt be put on and taken off; do I have to remove the hat to do it?

• Durability: How well does it resist getting dirty? Is it easy to clean, and does it clean up well? How tough is it (i.e., how well does it hold up under “normal use”)? How does it hold up to repeated donning and doffing?

My Expectations For The Or Sahara Cap
Following are my expectations for this Cap, stated as hypotheses. I will test these hypotheses to determine if they are true or not.

• The OR Sahara Cap will be well designed so it fits well, is very functional, and looks good. (True, the cap is very well designed and constructed. It fits well except for the elastic being too tight on the top back of the skirt.)
  

• The Sahara Cap with the skirt on will provide excellent sun protection.
  

• The Sahara Cap with the skirt will be acceptably comfortable in hotter weather and when hiking uphill with a backpack on.
  

• The Cap will be convenient to adjust for wearing over a helmet liner or balaclava.
  

• The Sahara Cap will be stable in the wind, with or without the skirt.
  

• The Sahara Cap can be used to provide sun protection for a variety of outdoor activities.
  

• The Sahara Cap will be a very lightweight and functional component of an ultralight backpacking system
  

• The Cap will not get dirty easily, and will launder well without damage or retaining stains.
  

• The OR Sahara Cap will be adequately durable for normal use in a variety of terrains, climates, and weather conditions.
  

• The Cap will be very versatile and perform well in a variety of outdoor activities.

Personal Information
Name: Will Rietveld
Age: 61
Gender: Male
Height: 6 ft (183 cm)
Weight: 170 lb (77 kg)
Head Circumference: 22.5 in (57 cm)
Email: (willi_wabbit at bresnan dot net) willi_wabbit@bresnan.net
City & State: Durango, Colorado 81301 USA
Location for Testing: Southwestern US (Colorado, Utah, Arizona, New Mexico).

Backpacking Background
I have been an avid backpacker for 46 years. Backpacking is my passion. I am retired and in excellent physical condition. In the fall, winter, and spring I backpack in UT, AZ, and NM. In the summer I backpack in several wilderness areas in southern Colorado. Backpacking Style—I have been a lightweight backpacker for many years, and an ultralight backpacker for 5 years. My wife and I give presentations on ultralight backpacking in the local area, and have developed a website called Southwest Ultralight Backpacking to share our information.

Acknowledgements
I would like to thank Outdoor Research and the BackpackGearTest Group for selecting me to participate in this product test.

Will Rietveld