How to Design Your Own Gangster Hat

Fedora hats are a must for any gangster costume

Dressing up as a gangster for Halloween is very popular costume choice. A gangster hat can be worn by men or women and when properly made, can be reused. You can usually find a fedora at garage sales or consignment shops, since they seem to go in and out of fashion, but if you want to design and make your own for a specific costume, refurbishing an old hat or using a kit is your best bet, unless you are an accomplished hat maker.

Things You'll Need

• Measuring tape
• Hat block
• Sandpaper
• Washcloth
• Felt hat body
• Water
• Iron
• Pins
• Wide ribbon
• Jaunty feather
• Glue

Instructions

Preparing the Hat Block

1. Take the hat block out of all the packaging. Hat blocks look like plaster. They usually have a thin layer of plaster-like substance on the outside so that it can be customizable to varying hat sizes. There will be markings on where to sand for the dip at the top of the fedora, but if you want it to look slightly different, feel free to experiment with your own design. Just be sure that the top isn't too deep, or it could alter the fit of your finished hat.

2. Measure your hat size. There will be markings on the plaster for varying hat sizes, so you will need to sand around to the specific size.

3. Sand the plaster according to the manufacturer's instructions. It will be messy, so you might want to do it outside.

4. Dampen the plaster and be sure that all the sanding is exactly as you want it.

Stretching the Fabric

1. Unwrap the felt and dispose of the packaging. There is usually some cardboard stuck between the layers of felt. Keep it in case you need it later.

2. Turn your iron to its highest steaming setting.

3. Steam the fabric so that it is damp but not wet.

4. Stretch the fabric over the hat block. (There should be a sticker or other marking that indicates where the top should be to get you started.) Pin it tightly to the hat block so that the shape of all the dips and crevasses you sanded are visible under the felt.

5. Re-steam as needed so that the fabric conforms completely to the block. You will start to see the hat taking shape. Once the top of the fedora is set, it is time to cut and fold the brim.

6. Measure the width of the desired brim. Unpin part of the hat and cut evenly around the base of the hat. Usually the brim is 1 1/2 to 2 inches from the base of the hat.

7. Steam the part that you have unpinned, so that it is damp. Cut the excess fabric from the hat in sections, unpinning part, steaming and cutting so that you can be sure that it is even. Once the felt dries, it will be more malleable to shape as the bottom of the fedora.

Finishing Touches

1. Glue the ribbon around the base of the hat. Be sure that the felt is completely dry before attempting to glue.

2. Cut off the excess ribbon.

3. Insert a feather into the ribbon if desired.

Tips & Warnings

• Be sure to work slowly and cautiously if you've never made a hat before.

References

• MadeMan; How To Make A Fedora Hat; Tabitha Dye; September 2010
• Hat Shapers: Felt Hat Care