How to Make a Fedora Hat

You can buy a fedora hat from the store or you can make your own. Making your own hat will ensure that your hat is one of a kind. Once you have the supplies you can make as many unique looking hats as you want. Normally, you would need to purchase a hat block to make a felt hat, but you can make your own hat block with an old hat you have at home.

Here's what you'll need to make your hat:

• hat felt
• rope
• non-stick spray
• spray-on lacquer
• expandable foam
• old hat
• fine grain sandpaper
• large file or edge sander
• steamer or a sponge and some water   

Make your own hat block by buying a straw or felt hat at a thrift shop that you really like the shape of. You're just looking for a good shape. If the fabric, color or trim on the hat aren't to your liking that doesn't matter. This hat will just be the mold to shape your fedora hat block.

Spray the inside of that hat with a spray-on lacquer to harden it so it keeps its shape and let it dry.

Cut all the decorations and trimmings off the hat.

Spray non-stick cooking spray in the hat. Make sure you cover the entire inside completely.

Spray the inside of the hat with compressed, expandable foam from your local hardware store. Fill it up about halfway and let it dry for a day. Once dry, the foam will become your fedora hat block.

Once the foam is completely dry, take it out of the old fedora hat and sand it with a fine-grain sandpaper.

Use an edge sander or a file to make a ridge all the way around the hat block about a half inch from the bottom.

Get a sturdy rope that will fit into the grove you've just carved in your hat block. Loop it around and tie it to itself to create slipknot.

Steam a hat felt or wet the inside of it with a sponge to make it pliable.

Put the felt over your hat block. Grab the edges of the felt and pull it down firmly over the hat block. Shape and smooth your felt to the form of the hat block. Start at the top of the hat and work your way down. This will be the final shape of your fedora hat.

Put the rope around the outside of the hat felt for your fedora hat so it goes into the groove. Make sure the felt is pulled securely under the rope and pull the rope tight.

Continue shaping the hat until it's the shape you want it.

Let it dry overnight. The next day, remove the rope and take the hat felt off the form.

Decorate it with feathers or a band or whatever you like.

This is a great technique for making hats. I learned it from watching this video. I think it's helpful to watch it if you're more of a visual learner.