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  1. Darrell2688

    Busted Hat Company

    My wife said that Esther is a very good seamstress and I have to agree, how in the world did she sew the brim binding in that manner, when I looked at it, I thought that it was sewn in place using a sewing machine. I have tried to use a sewing machine and I can't sew in a straight line even with...
  2. Darrell2688

    Busted Hat Company

    I put the hat into the brim flange and steamed the part of the brim that I want to shape, then just worked on the steamed felt until it was in the shape that I wanted. Then removed the hat and let it dry until the next day, then steamed any area that wasn't shaped right, when I was happy with...
  3. Darrell2688

    Busted Hat Company

    I finished work on another hat today. I made it in an Indiana Jones style fedora, I used a brim flange for this hat, but I only used it to shape the back of the brim. The hat band is 1 1/2" Espresso, the sweatband is 2" wide, Chestnut color, white satin liner with silver piping, the brim has a...
  4. Darrell2688

    Busted Hat Company

    I like your fedora. There was a lot of work put into the hat band, really nice outstanding work, the brim binding would be a bit tough for me, all of my sewing is by hand.
  5. Darrell2688

    Busted Hat Company

    When I make a hat in 7 3/8" size, I use a 60 CM block 6" or 5.5" tall in regular oval and that works great with the leather sweatbands that I use in my hats. Using a spacer under a 6" tall block would also work to get the 7" tall open crown, my problem is I am working in limited space, so having...
  7. Darrell2688

    Busted Hat Company

    I would need a 63CM long oval block 7" tall to make a hat and a beaver fur felt hat body that would have enough felt to make a 3 1/2" wide brim. I think that I can get the block made, where to get the beaver felt would be the problem.
  8. Darrell2688

    Busted Hat Company

    Most of my hat sales have been in the 7 3/8" size, I have had 3 orders in the 57 CM, 7 1/8", 7 1/4.", I have sold about 20 hats so far, most were in 2023 and the sales have worked out pretty well, because I have been able to buy new fur felts, so I can make another hat. I made the bottle green...
  9. Darrell2688

    Busted Hat Company

    Making a blue Smokey Cover would be unUSMC if you put a Eagle, Globe and Anchor pin in the crown, the Georgia State Police wear a blue Smokey Cover, here in KY they wear a Gray Smokey, Alaska, Missouri and South Caroline wear a blue Smokey, it should be ok, just don't stick the Marine Corps pin...
  10. Darrell2688

    Busted Hat Company

    I will have to see if I can find the hat that Art made, I downloaded all of the photos of his work that I could find, that hat is not in my collection. Well NUTS. I will have to get a darker blue than the steel blue that I have, I think the Millinery Warehouse has a darker blue in stock that is...
  11. Darrell2688

    Busted Hat Company

    I don't understand the problem with the Campaign DI Cover, I liked those hats, however some of the DI's could scare the hell out of you, most of them were Nam veterans, called you everything except human and we had one that would throw a knife and stick in the door while we sat in formation...
  13. Darrell2688

    Busted Hat Company

    Yesterday I decided to change the hat band on the green hat, because I didn't like the way that it looked, plus my wife didn't like it either, so I changed the style of hat band, it is still a light blue. Here are some up to date photos. I still need to work my method of taking photos.
  14. Darrell2688

    Busted Hat Company

    Hi Randy, Thank you, I still need to do better with photos, I posted some on Ebay and for some reason a few of the photos have patches that look like the green hat has a wide dirt steak across the side of the hat, I think my camera acted like a mirror and reflecked light back onto the felt, so...
  15. Darrell2688

    Busted Hat Company

    Hi Brent, Thank you. I post my hats on Ebay for sale or buy now. I think Ebay hits you with higher fees when you post something for auction. I still need to get a 63CM long oval to make a hat in your size. What is your favorite hat style, dress fedora or western? Do I need to purchase a black...
  16. Darrell2688

    Busted Hat Company

    Well it has been a little while since I posted anything new that I have made, yesterday I finished the work on the Bottle Green Fedora hat and the Ebay ad will be active tonight around 7PM California time. Ebay has made some changes to the way you list items for sale, so far I am not fond of...
  17. Darrell2688

    Hat making?? Learning Millinery..

    I don't have the money to buy beaver fur felts to work with, it would be nice to have a beaver hat body to work with just for the experience. To figure out the selling price, if I was able to make Western hats of beaver that were custom made to fit the customer and my local competition was...
  19. Darrell2688

    Hat making?? Learning Millinery..

    My wife had a knee replacement surgery this past Tuesday, so my hat work has come to close to a total stop, I am a little busy taking care of her and some cooking, cleaning, next week she gets to start therapy sessions 1 hour long, round trips will be another hour, so far I have been able to get...
  20. Darrell2688

    Hat making?? Learning Millinery..

    Well if you end up with a hat that has burnt splotches, there is only one thing left to do, use a small hand held torch and turn it into a new design, use a paisley print scarf for a hat band, add a length of leather shoe lace and sell it as one of the new styles of hats, see if you can sell at...
  21. Darrell2688

    Hat making?? Learning Millinery..

    I like straight sides on my blocks. However if you contact Clint you can tell him how you want your blocks made and he will work up a program for the CNC machine to follow, he can make the top of the block totally round. He has a program in his CNC machine for brim flanges that he would like to...
  22. Darrell2688

    Hat making?? Learning Millinery..

    Contact Clint and ask him to make you a 51 style with straight sides, he can make blocks with more of a rounded crown. The 52 block is a good block to have, it would be a good idea to have both hat block styles, gives you more choices to work with. Hat blocks are a one of the things that you...
  23. Darrell2688

    Hat making?? Learning Millinery..

    Is that a 51 or 52 style hat block? From this view it looks like a 52 with straight sides? Clint is using 2 CNC machines now, one to cut the rounded area of the top of the block, the other cuts the bottom sections. Clint told me that the machine that cuts the rounded section takes about 50...

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