Creating Your Custom Hat
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The fascinating story it tells, however makes it well worth the wait!



The finest custom hats begin as felt pressed from beaver, rabbit or other fine fur.




The hat is blocked and sized using a turn-of-the-century machine
so rare that fewer than ten exist in the world!




A Rounding Jack is used to hand-cut the brim to its correct size.




The brim is flanged using a special wooden flanging form and a high-pressure steam iron.




This machine, called a Pouncer, is used to sand and smooth the finish of the hat.



Once this step is completed, final finishing of the felt is accomplished by hand-pouncing with special finishing powders.


Final shaping of the hat is provided by special wood forms.
Many of the forms seen in this collection are nearly 100 years old!




The satin inner lining and sheepskin leather sweatband are hand-cut and hand-sewn, never glued, into the inside of the hat. Then, using the finest grosgrain ribbon, the outer decoration is similarly hand-sewn into place.




Sizing and Fitting your Custom Hat

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