How to Make a Fedora

The detectives in the 1940's donned an old but trusty fedora. Crumpled with character, allowing the front to drop to shadow the eyes, the fedora was seen on many a cinema character. If you've always wanted to create the hat that says,"Here's looking at you, kid," you now have the opportunity.

Difficulty:

Moderate

Instructions

Things You'll Need

• Pre-made hat block, or sheets of Styrofoam glued together
• Plastic wrap
• T-pins
• Rubber bands
• Felt
• Water
• Scissors
• White glue
• Paint brush for glue
• Seam binding or grosgrain ribbon
• Press cloth
• Iron
• Carpet thread
• Needle
• Hat wire

Making the Crown

1. Purchase or create your own block to form the hat. If you create your own block, you can either glue several sheets of Styrofoam together and cut to shape. Otherwise, purchase a block. Cover the homemade block with plastic wrap and hold down with rubber bands and pins.

2. Wet the felt thoroughly that you are going to be using. Scrunch it slightly and pull flat. Center the felt onto the form.

3. Affix a T-pin at the top to hold. Pull the material gently down at the sides. Once each of the 4 sides have been pulled connect them to the block at the base with a pin.

4. Remove the pin on each side as you vigorously work the felt downward. Place a rubber band around the pin line at the base.

5. Coat the felt on the form with white glue with a brush and apply a second layer of felt to the first. Use the same steps as you did with the first layer. Allow it to thoroughly dry.

6. Remove the crown from the form and clip at the base of the crown, removing excess material.

Making the Brim

1. Cut out two sheets of felt that are 2 inches bigger than the size of the brim that you desire.

2. Wet the sheets thoroughly. Paint glue over one sheet and sandwich the sheets together. Allow them to dry slightly.

3. Calculate when the sheets are still damp, but not totally wet. Using an iron and covering with a press cloth, press the felt.

4. Cut a hole in the center for the crown while the felt is damp yet stuck together. Make the hole in the center that's 1 inch smaller than the crown, so there will be material to stitch.

5. Shape the outside of the brim. Pull it down over the crown on the hat block. Allow it to dry to assume the shape. Remove both when dry.

Finishing the Fedora

1. Place the crown atop the brim. Stitch them together using a strong thread such as a carpet thread.

2. Stiffen the brim edge with hat wire zigzag stitched on the outside edge, if necessary. Cover it with seam binding or ribbon.

3. Stabilize the hat band by stitching grosgrain ribbon on the inside to cover the connection of the brim and create a hat band.

4. Wear the fedora proudly.

Tips & Warnings

• You will need to cut your forms to look like the fedora. If you don't have a pattern, it's best to purchase a block.

Resources

• Purchase a Fedora Hat Shaper at Hat Shapers.