How Felt Hats Are Made
Based on a customer's order, a felt hat body is steam blocked
to a specific head size, crown shape and brim width. Then a stiffening
machine is used to apply shellac to the brims for firmness.
The crown iron machine is used to tighten and to smooth the felt
The brim is cut to the customers desired width before
finishing. The brims are greased and pounced many rounds, using very fine
sandpaper to achieve the proper finish. D-machines are used to grease and
pounce the crowns. This is the finishing operation
where the felt is sanded down to create a very smooth and fine
finish for the felt hat.
A specially mixed powder, matched to the hat color, is hand rubbed into the body
to enhance and even the tone.
Crown press machines are used to shape the crowns. Steam is used to restore
the smooth finish and to clean the hat in the inspection line before a
custom made 103 Singer sewing machine is used to sew the lining into the hat.
Boxes uniquely designed to protect the hat in transit receive the