Yes, I did not know either. I had suggested to the customer we remove the binding and then add a row of slightly contrasting stitching. But the felt was soft/thick so I figured it was worth a shot to try. It worked out much better than I thought. It might not work as well on a stiffer felt as the steam might not collapse the stitching holes.
The guy might be on to something!Maybe they thought it would even out the wear and the sweat band would last longer.
Most block makers that I deal with are one man shops, they are craftsmen/artisans and can make the blocks to your spec. I have blocks from many makers and many vintage as well. The vintage blocks tend to have the smaller diametre holes but not necessarily. The holes seem to be of two sizes. I don't have any powered spinners just do it by hand . I have a few block stands with varying diametres of pipe so it doesn't matter to me.
I appreciate the reply. I know that the few block makers out there today seem to be pretty flexible with custom features. I'm wondering as far as all of the old factory made hat blocks out there if there was one or two standard hole sizes or if it varies between the different makers? I'd like to be able to accommodate most blocks that are out there, so if there was a standard smaller hole size I could make the spindle that size with a sleeve that can be used for the 1 inch holes.
I have two sizes. I will be in the shop later and will throw the caliper on them and let you know.
Awesome. I appreciate it
I measured 3 of my vintage blocks. All 3 are different: 10, 12.5 and 15mm. Although the 15 mm one has no metal reinforcment only wooden so it could have been enlarged over the years.
Yes, my new blocks all have the larger holes.
John Lofgren Monkey Boots Shinki Horsebuttt - $1,136 The classic monkey boot silhouette in an incredibly rich Shinki russet horse leather. 
Grant Stone Diesel Boot Dark Olive Chromexcel - $395 Goodyear welted, Horween Chromexcel, classic good looks. 
Schott 568 Vandals Jacket - $1,250 The classic Perfecto motorcycle jacket, in a very special limited-edition Schott double rider style. Thanks. It seems like most of the new ones I have seen are 1" or just over. A few of the vintage ones that I have are also 1" and one is 3/4"ish but wallowed out pretty good so it's around 7/8" now. I'm thinking maybe 3/4" was a common size also from some pictures I've seen.
As most things the answer is: it depends. What style? How wide a brim? I have a number of the 95 gram beaver I made for myself with 3" brims. I flanged them with just a very slight cupping and then bound the brim. That was enough to give the brim structure and I did not need any shellac
Thanks for the feedback. I was more concern about the crown holding the crease than the brim. I'll give it a try with what I have and see how they turn out.
I love the crowns on my 95gr felts. They are the closest I have found to replicating that vintage softness/yet substance. To my needs they stay bashed really well. I have a Commano, Flagstone, and a Silverbelly...all with 6" crowns.
