Pa, you are showing some tight creasing skills! Are you reading Ermatinger, or just experimenting? Either way, you are doing good work! You seem to have a sculptor's way, much like my buddy T. Jones...
I agree with Landman. This matches my experience, except when a liner is very floppy, in which case it can be steamed and maybe even lightly starched back to shape over a block or can. I never glue liners on any hat. I stitch them. On my own personal hats, I sometimes tape them with strips...
Pretty decent analysis. Detergent also helps with the felting process, although I cannot recall the mechanism. Motion would seem to help the fibers bind, as it is the wet heat & kneading motion on the battery that makes the fibers felt in the first place.
Go to the ranch in Sonoma if you can. It will blow your mind. I went as a child, but still remember lifted and rotating feeding troughs for hogs, so they had to stand and walk on their hind legs and their hams would consequently be bigger, and also concrete floors with gutters in the pig pens...
It is my understanding that lacquer is not water soluble, so rain should neither break it down nor wash it away. I imagine that the heat that softens the lacquer also allows it to reform more soundly...
It's hard for me to fathom that this discussion has devolved to the point that banning one of the premier custom hatters in the world from the Fedora Lounge is even a topic of conversation.
I agree that it does not look like a pork pie. I can't say with certainty, but the joker hat looks like a real flat top. Like this costume hat sold contemporaneously with the 1989 movie:
And this real hat, found online:
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