Bill, A couple of questions about “Clear stencil sheet”. When I put that search into Amazon I got: Grafix Clear Craft Plastic .007 Thickness 12-Inch by 12-Inch, Pack of 25 Does this sound like the same stuff? Also, are you saying that you can thermoform this? Any other reasons why this is your favorite? (scratch resistant or just the clarity) Brian
Go to your local welding supply and get a sheepskin sweatband.
They have snaps and make the band much more comfortable.
They look like: http://store.cyberweld.com/coshsw.html
Tillman Sheepskin Headgear Sweatband 560 - $5.95