Prometheus Design Werx

Apex Boonie Hat

59.00
Overview

The PDW Apex Boonie Hat is a modern interpretation of a Vietnam Era classic, built on the RECCE short brim, a field modification born in the jungles of Vietnam that produced the most functionally refined sun hat profile in the history of outdoor headwear. Custom-milled 2-way stretch NYCO+ Ripstop, a bug-proof NoSeeUm mesh liner, synthetic micro-suede sweatband, and a cinching crown fit system update every detail that made the original work. Available in Universal Field Gray, All Terrain Brown, and Ranger Green.

A Classic Piece of
Headwear Born
Over 60 Years Ago
Out of Necessity

The boonie hat is one of those rare pieces of equipment that transcended its origins so completely that most people wearing one today have no idea where it came from. It started as improvised headwear sewn by Vietnamese tailors from salvaged parachute fabric, made its way into the field with American troops in the early 1960s, and within a decade became standard issue across all branches of the U.S. Armed Forces. For over half a century the design held. That kind of longevity does not happen by accident. It happens when a piece of equipment solves a problem so well that no one can improve on the core concept. For the full history of the boonie hat and the design decisions behind the Apex, read our field notes on PDW Dispatches.


At Prometheus Design Werx, the approach every piece of equipment the same way: is to identify what works, understand why it works, then apply contemporary materials science and design thinking to push the concept forward without losing the functional DNA that made it essential in the first place. The Apex Boonie is a refinement, not a reinvention.

Custom Milled
NYCO + Stretch
Ripstop Fabric

6.5oz nylon/cotton (NYCO) ripstop fabric has been the MILSPEC standard for decades. Why? Because it works and works well over a wide variety of conditions and environments. PDW believed there was room for improvement, was not beholden to a military procurement spec, and believed that adding a percentage of stretch would notably improve the performance, hand and comfort of NYCO ripstop. And it did. This custom-milled NYCO+ Ripstop is a purpose-built technical fabric. The high cotton content breathes naturally against the skin, the high-tenacity nylon provides field-grade durability, and the 3% Spandex adds stretch and recovery that no standard boonie fabric offers.

Loop Panel for Personalized Add-Ons

A loop field on the front panel takes patches, insignia, or any personal mark you want to carry.

Dialed-In Fit:
Cinching Crown
and Chin Strap

This Boonie Hat is designed with an adjustable shock cord system around the crown. This allows the wearer to totally dial in the fit for comfort to security when worn during higher speed pursuits. Additional hat retention comes in the form the classic chin strap which can also be cinched from the back for those who prefer it.

Engineered Slit
Vents for Airflow

Totally unique to the PDW Apex Boonie Hat is the engineered slit vents for airflow. This retains the classic nature of the hat construction and styling, while allowing airflow inside the hat for breathability. Gone are the generic metal screens which can be uncomfortable when pressed against the head and inevitably turn green from corrosion when used around sea water.

Bug-Proof
NoSeeUm Mesh

To perfectly pair with the slit vents, this design uses a bug-proof NoSeeUm mesh liner. The very same material used in lightweight backpacking tents to keep those pesky little bugs out. 

Synthetic Suede
Sweatband

PDW pays attention to the details. This design utilizes a synthetic micro-suede sweatband that dramatically improves comfort in hot conditions, but also helps in preventing friction rashes.

Classic Interior
Map Pocket

Every self-respecting boonie hat needs the classic inside map pocket. Made from a lightweight, durable 70D nylon ripstop in vintage orange, the map pocket is a holdover from military users. You can use it to stash a wilderness permit, trail pass, fishing license, or a laminated photo of your loved ones for good luck.

Custom Tailored
in Vietnam

After many years of sampling and prototyping with manufacturing partners domestically and abroad, the decision was made to produce the Apex Boonie Hat in the country where this style was born, Vietnam. Over 60 years ago, the skilled mom and pop tailors who originally made these for SF operating in-country, have evolved into technically advanced manufacturing centers that can confidently handle the more complex design requirements of the Apex Boonie Hat. Vietnam leads the globe when it comes to technical sewing and producing this boonie hat there was a homecoming. 

PDW Apex Boonie Hat packrafting PFD Amphibious Delta Cargo Shorts

FAQ:

 

What is the RECCE brim and how does it differ from a standard boonie?

 

The RECCE cut originated with Vietnam-era reconnaissance teams who trimmed their brim widths to improve peripheral vision during close-quarters jungle movement. The Apex Boonie follows this low-profile brim pattern, providing meaningful sun coverage across the face and neck while keeping the silhouette clean and unobtrusive. It wears like a boonie but carries none of the oversized mushroom cap look of most military surplus offerings.

 

What sizing should I order?

 

The Apex Boonie is available in two sizes: S/M fits head circumference of 20.41" - 23.16", and M/L fits 23.16" - 24.34". The cinching crown system allows fine-tuning within each size range, so if you fall between sizes, choose the larger and dial it in with the crown adjustment.

 

What colorways are available?

 

The Apex Boonie Hat is available in three colorways: Universal Field Gray, All Terrain Brown, and Ranger Green. Each color is suited to a broad range of environments, from alpine and urban to riparian and tropical.

 

Is the Noseeum mesh liner actually effective against insects?

 

NoSeeUm mesh is a fine-weave netting developed for backpacking tent construction, specifically designed to block the smallest biting insects including no-see-ums (biting midges) that pass through standard mosquito netting. The mesh liner in the Apex Boonie vents air through the crown while blocking insects at each vent opening.

 

Why is the Apex Boonie Hat made in Vietnam?

 

Vietnam is the birthplace of the modern boonie hat. The sewing workshops that produced the first locally made boonies in the 1960s established a garment manufacturing tradition that today serves the world's leading technical outdoor and premium apparel brands. Manufacturing the Apex Boonie in Vietnam is a direct acknowledgment of that lineage, and an intentional choice to adhere to quality.

 

Can the hat be packed flat?

 

Yes. The 2-way stretch NYCO+ Ripstop shell and soft construction allow the Apex Boonie to be rolled or packed flat without permanent creasing. It returns to its original shape when worn.

 

How do I care for the Apex Boonie Hat?

 

Machine wash cold, gentle cycle. Tumble dry low or hang to dry. Do not iron the slit vents or NoSeeUm mesh panels.

Product Specs

Materials:

  • 6.8oz, 55% Cotton / 42% High Tenacity N6 Nylon / 3% Spandex NYCO+ Ripstop
  • 70D Nylon Ripstop
  • Poly Synthetic Micro-Suede
  • Nylon Noseeum Mesh
  • Custom Nylon Slotted Buttons
  • Custom Nylon Toggle Locks
  • Poly Flat Lace
  • T40 Nylon Thread

Sizing:

  • S/M: Circumference 20.41" - 23.16"
  • M/L: Circumference 23.16" - 24.34"

Features:

  • Custom Milled 2-Way Stretch Technical Ripstop Fabric
  • Interior Map Pocket
  • Bug-Proof Noseeum Mesh Liner
  • Soft, Low Profile Slit Vents for Air Flow
  • Synthetic Micro-Suede Sweatband
  • Cinching Crown for Dialed in Fit
  • Cinching Chin Strap
  • Classic Foliage/Accessory Loops for Camo Add-Ons While Stealthy Tracking Sasquatch to Securing Those Woolly Buggers to Fancy Dancers
  • Rear Loop Panel: Cate Eyes, Insignia, Reflective Tape

Custom Tailored In:

  • Vietnam, the Country Where the Boonie Hat Was Born

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