The US army had forage/fatigue caps as early as 1803. Unfortunately no example survives. Tom DeVoe, in a reply to a similar query in EMPIRE EAGLE & LIONS [issue 100], The US Napoleonic magazine, guesses that it would have been like the Britsih 'pork-pie' cap, brimless, shapeless circle of blue material with sides of red, with perhaps white tape at the seams.
Replies 5: U.S. Headgear War of 1812
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Shakos and Leather Cap
Light Dragoon Helmet 1812
Officer's Cocked Hat (Or Chapeaux) and Other Examples
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