The Making of Cowboy Hats (Pg. 3)
The final shrinking process, called “final sizing,” is the last process done before the hood is shaped into a cowboy hat. In this process, a series of three rollers are used over a hot water bath and is done only after the hood has been dyed to the proper color. The final sizing shrinks the fabric to its correct and final size before being formed into a cowboy hat.
Stiffening and blocking are two more processes that occur in the making of a cowboy hat. Although these steps may vary by manufacturer and style of hat, both are usually done by hand to ensure a quality cowboy hat is produced. The cowboy hats are now ready to be sold.
When a cowboy hat is purchased, the sales person can further shape and customize each cowboy hat to the liking of the customer. This is done by adding or taking away creases and dents, and by shaping the brim. Also, the brim size can be reduced using a brim tool.
A straw cowboy hat is made much the same way as a felt cowboy hat. However, there are only three processes needed to make straw cowboy hats: preparing the straw, blocking, and machining.