process

Step One

The hat body is selected based on the customer's material and color selection.

Step Two

Next, the hat is plated to set the brim break line by applying pressure and heat to flatten the brim.

Our plating press is custom-made by Buckaroo Hatters and is in use by multiple hatters nationwide.

Step Three

After plating, the hat is placed on a metal sheet to draw the heat from the brim quickly and set the break.

Step Four

While the hat cools, the correct sizing ring is chosen and inserted into the finger blocker.

Step Five

After sizing ring selection, the hat body is placed in the finger blocker, and held in place by the 42 fingers.

Step Six

Next, the hat block is selected and inserted into the finger blocker. This sets the hat's crown and size.

Step Seven

Finally, the finger blocker is started and the hat block is pressed into the hat's crown.

Step Eight

As the finger blocker presses the block, the steam softens the hat fibers and allows the hat to take the shape of the chosen block.

Step Nine

Once the steam has settled and the blocking is finished, the hat is removed to be prepared for the next step.

Step Ten

Next, hatter's string is tied tightly around the crown where it meets the brim.

Step 11

The hatter's string prevents hat body slippage during the sanding process.