Custom cowboy hats, hand-blocked in East Aurora
We measure your head, block the felt on the bench, and shape the crown and brim for how you actually wear a hat — work, riding, or Sunday morning coffee. About 30 minutes of fitting, two to three weeks to build.
Book a fitting Call (716) 555-0142
How a made-to-order hat works
- Measure. A cloth tape around the head, just above the ears, where the hat will sit. We write down the number and the shape of your head, not just the size.
- Choose the felt. Weight, finish and colour. Lighter weights crease crisply and dress up; heavier weights take a beating and hold a deep cattleman crease.
- Pick a crown and brim. Crown height, dent and pinch; brim width and curl. We will show you samples on your head, in the mirror, before anything is cut.
- Block and shape. The felt is steamed, blocked to size and set. This is the part that makes a hat fit the person rather than a size chart.
- Finish. Sweatband, liner, band, and a stamp if you want one. Then we call you when it is ready.
Felt or straw?
| If you need… | Choose | Starts at | Life span |
|---|---|---|---|
| Cold, rain and a hat you reshape for years | Fur felt | $395 | 10–30 years with care |
| Summer shade, work, festivals, backups | Shantung straw | $85 | 2–5 seasons |
| A hat that lives in a truck and gets crushed | Straw, then steam it back | $85 | Replace sooner, worry less |
| Restoring grandfather's felt | Cleaning and reshaping | $35 | Depends on the felt |
Sizing guide
Measure with a cloth tape, snug but not tight, around the widest part of your head about a half inch above the ears. Compare with the table; if you land between two sizes, go up and we will pad the sweatband.
| Head (inches) | Hat size | Typical fit |
|---|---|---|
| 21 5/8 | 6 7/8 | Small |
| 22 | 7 | Small–medium |
| 22 3/8 | 7 1/8 | Medium |
| 22 3/4 | 7 1/4 | Medium–large |
| 23 1/8 | 7 3/8 | Large |
| 23 1/2 | 7 1/2 | Large–XL |
| 24 | 7 5/8 | XL |
Serving Buffalo and Western New York
Customers come to the bench from Buffalo, Orchard Park, Hamburg, Amherst, Williamsville, Holland and Colden — anywhere within about half an hour of the village. If the drive is too long, we can fit you by video: send four photos (front, side, back and a tape measure around the head) and we will confirm the size before blocking.
Ask us about our hat care guide: cleaning and reshaping a cowboy hat at home, and felt versus straw.
Common questions
How much does a custom cowboy hat cost?
Made-to-order fur felt starts at $395. Straw starts at $85. Reshaping an existing hat is $35 when it does not need new parts. Fittings are free with a purchase.
How long does it take?
Felt usually two to three weeks after the fitting; straw is often same-week. We call or text when it is ready.
Do I need an appointment?
Walk-ins are welcome for sizing, steam shaping and repairs. A full custom fitting is best booked ahead so the bench is free.
Can you ship it?
Yes — insured with tracking across the United States, and to Canada on request.
Will you work on a hat I bought elsewhere?
Usually yes. Bring it in and we will check the felt, sweatband and crown before you spend anything.