5-Panel Poplin Cap

[Just Sew It]

Trying to embroider 2 doz of these 5-panel poplin caps with a stiff poplin in the front instead of buckrum.I have moved the design down as far as I can and hooped the hats away from the frame a little. Three needle breaks up near the peak of the hat, and one made a pleat with the lettering right at the top. I would appreciate any advice on hooping these hats. They just sit so far away from the needle plate! I've tried several cap backing weights, next is 2oz.
Thanks to anyone who can help.

[Steve]

What is the size of the design? It might be too big for caps. What needle are you using? You should be using a sharp point needle for caps since the material is stiffer than a shirt. Is the cap puckering or pulling? Make sure the cap is tight when it is hooped. Tearaway should be fine for just about all caps. Half the caps I do, I don't even use backing. Who makes the caps you are sewing on?

[Just Sew It]

The design works fine on all the 6-panel hats. It isn't size, it is the hat. Outdoor Cap makes it. The stiff poplin collapses under the pattern and makes hills around the pattern for the lettering to go on. I use sharp titanium needles.

[Just Sew It]

Larry, That didn't work. Broke another needle at the top of the lettering. If I can get help, I'll try to make the lettering sew from the center out. Don't have time to work on it very long as 5 dozen hats are waiting.