The Process
1. Choice of felt
The first step is choosing which felt and color fits your preference. We use primarily 100% Coypu (Nutria) fur felt, as well as 100% rabbit fur felt. Both qualities come in a bevy of unique colors.
2. Steaming
In order to be blocked, the felt must be saturated with steam in order to make the felt soft and malleable.
3. Blocking
Once steamed up, the felt is pulled over an open crown hat block corresponding to the clients head size. The felt is tied off at the base of the block using a blocking tie and the brim is ironed out flat.
4. Pouncing
“Pouncing” is hat maker slang for sanding. When the felt is dry, we use an electric sander to shave off excess fur. Top and bottom. Using finer and finer sandpaper, this makes each hat’s finish smooth to the touch.
5. Sweatband
Using an ASM 1107 sewing machine specifically designed for sewing in sweatbands, each hat includes a quality leather sweatband.
6. Shaping
Using steam, each hat is hand shaped to the clients specifications and preference. This includes the crown and brim.
7. Style