The journey from raw material to finished hat is a long one, and our professional hatters have trained for years to become experts at the process.

From hat body selection to completion, the hatter will spend an average of eight to ten hours on a single hat. Unlike the mass-produced hats coming from factories and major manufacturers, everyone of our hats are inspected over every inch to ensure every customer gets the hat they want. Check out the slideshow below for a quick overview of how a hat body goes from shelf to customer, and then, be sure to check out the various styles we make here at Buckaroo Hatters!

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Hat Body Selection -
The hat body is selected based on customer material and color selection.
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Hat Body Selection
Hat Plating
Cooling
Sizing Ring
Hat Set in Finger Blocker
Hat Block Selection
Hat Block Insertion
Finger Blocker Set
Blocking Complete
Hatter's String
Hatter's String
Crown Sander
Crown Sander
Crown Sander
Hand Sanding
Hand Sanding
Crown Iron
Crown Iron
Crown Singeing
Hat Singeing
Final Hand Sanding
Hat Plating
Cooling
Brim Jigger
Brim Jigger
Hat Plating
Brim Cutter
Brim Cutter
Sweat Band
Sweat Band
Sweat Band
Sweat Band
Sweat Band
Bound Edge
Bound Edge
Bound Edge
Bound Edge
Hat Shaping
Completed Hat
Shadow
Slider