My Hat-Making Process

Handcrafted Felt Hats with Story and Soul

Every hat I make begins with intention. Sometimes it’s a quiet thought, sometimes it’s a clear vision—but always, it starts with purpose. Whether it’s a weathered cowboy hat or a sharp fedora, each one is shaped by hand, with care, patience, and deep respect for the craft.

1. Selecting the Felt 

It all starts with the material. I work with high-quality wool and fur blends that are durable, rich in texture, and age beautifully. I take my time choosing the right felt—something that feels alive in the hands and ready to become something lasting.

2. Blocking the Crown

The felt is steamed and softened, then pulled down over a wooden block to shape the crown. Whether it's a flat-top, telescope, or teardrop, I form each shape by hand, letting the hat guide me. No two crowns are ever exactly the same—and that’s the beauty of it.

3. Shaping the Brim

Once the crown is set, I move to the brim. I trim it to size, steam it again, and shape it by hand—flat, curled, or snapped depending on the look and feel I want. The brim gives the hat its presence, and I always aim to honor that with balance and character.

4. Sanding and Distressing

Some hats are meant to feel like they’ve lived a little. I’ll sand, brush, or distress the felt to give it a rugged, worn-in soul. These small marks and textures bring depth—each one telling part of the story.

5. Hand-Sewn Sweatband

Inside, I hand-sew the sweatband for comfort, structure, and tradition. This step takes time, but it’s essential. It’s where craft meets function, and it helps the hat keep its shape while staying comfortable for the wearer.

6. Hatband & Final Touches

Here’s where I bring in the spirit. Each hatband is created individually—grosgrain ribbon, leather cord, jute twine, bandanas, found objects, and accents like feathers, copper, or cards. Every detail is chosen to reflect a story, a vibe, a sense of place.

7. Final Steam & Setting

Once everything’s in place, I give the hat a final steam and shaping. I check every line, curve, and detail before letting the hat rest. When it’s ready, it’s not just a piece of headwear—it’s something personal. Something made to be lived in.

Every hat that leaves my hands is one-of-a-kind—shaped with care and built to last. I make each one for someone who values craft, story, and the journey they’re walking.