Modify a Flange?

[wiscohatguy]

Recently I began delving into the world of hat making tools, with the idea of potentially making my own hat some day, but moreover taking care of the hats that I already own. Today I received a block and flange combo that I purchased for what I believe to be a very good deal on ebay. They appear to be in great condition, and I still think I scored a bargain, but... one little problem. While the block is indeed my size, as advertised, a 7, the flange is two sizes smaller at 6 3/4. While I bet that I could re-sell it, I would hate to part with the flange because its width is perfect for some of my slightly wider brims, and I think it's got a nice shape that closely matches several of my hats.

When I insert the 7 block into the 6 3/4 flange, it becomes rather apparent that the difference between 7 and 6 3/4 actually isn't huge with regards to circumference. It seems that carefully removing a measured bit of material would do the trick. Has anyone here modified a flange in this way, to make it accommodate a larger hat/head size? I suppose I am wondering how precise the "opening" of the flange needs to be, in regards to the angle of the inner walls, if that makes sense? Or does that not matter, and really the only thing that matters is the size of the hole? Also, if no one has done this, would you caution against it?? Does this sound like sacrilege for an amateur hat enthusiast to attempt modifying an antique piece that a professional hatter could really get some use out of?? Does anyone even have a 6 3/4 head????

 

[belfastboy]

Recently I began delving into the world of hat making tools, with the idea of potentially making my own hat some day, but moreover taking care of the hats that I already own. Today I received a block and flange combo that I purchased for what I believe to be a very good deal on ebay. They appear to be in great condition, and I still think I scored a bargain, but... one little problem. While the block is indeed my size, as advertised, a 7, the flange is two sizes smaller at 6 3/4. While I bet that I could re-sell it, I would hate to part with the flange because its width is perfect for some of my slightly wider brims, and I think it's got a nice shape that closely matches several of my hats.

When I insert the 7 block into the 6 3/4 flange, it becomes rather apparent that the difference between 7 and 6 3/4 actually isn't huge with regards to circumference. It seems that carefully removing a measured bit of material would do the trick. Has anyone here modified a flange in this way, to make it accommodate a larger hat/head size? I suppose I am wondering how precise the "opening" of the flange needs to be, in regards to the angle of the inner walls, if that makes sense? Or does that not matter, and really the only thing that matters is the size of the hole? Also, if no one has done this, would you caution against it?? Does this sound like sacrilege for an amateur hat enthusiast to attempt modifying an antique piece that a professional hatter could really get some use out of?? Does anyone even have a 6 3/4 head????

I have made my own flanges so know the process. If you are a size 7 then the hole in the flange needs to be larger to accommodate the thickness of the felt. So you would need to remove a fair bit of wood to get it to fit....but realize that as flanges are sized to suit the brim width desired your flange will be shorter than you likely want. Also, realize that the block (if making a hat for yourself) needs to be one size up from your head measurement. I am a size 59cm so I block on a size 60cm. The leather sweat band takes up the 1cm.

 

[belfastboy]

I have made my own flanges so know the process. If you are a size 7 then the hole in the flange needs to be larger to accommodate the thickness of the felt. So you would need to remove a fair bit of wood to get it to fit....but realize that as flanges are sized to suit the brim width desired your flange will be shorter than you likely want. Also, realize that the block (if making a hat for yourself) needs to be one size up from your head measurement. I am a size 59cm so I block on a size 60cm. The leather sweat band takes up the 1cm.

I have made my own flanges so know the process. If you are a size 7 then the hole in the flange needs to be larger to accommodate the thickness of the felt. So you would need to remove a fair bit of wood to get it to fit....but realize that as flanges are sized to suit the brim width desired your flange will be shorter than you likely want. Also, realize that the block (if making a hat for yourself) needs to be one size up from your head measurement. I am a size 59cm so I block on a size 60cm. The leather sweat band takes up the 1cm.

Removing the excess wood requires the use of a router and you will need to make a template circle to clamp to the flange so you will have a guide for the router to follow. You cannot freehand it and likely have it turn out well.

 

[belfastboy]

Removing the excess wood requires the use of a router and you will need to make a template circle to clamp to the flange so you will have a guide for the router to follow. You cannot freehand it and likely have it turn out well.

It may, in the end, be more efficient to sell the flange (although flanges that small are not in great demand) and start fresh by buying a flange in the correct size. Perhaps look into 3D printed blocks and flanges as they can be had for much cheaper than wood and you can buy a matched set with the exact size and profile for the block, the exact width and profile for the flange.

 

[Jon Crow]

It may, in the end, be more efficient to sell the flange (although flanges that small are not in great demand) and start fresh by buying a flange in the correct size. Perhaps look into 3D printed blocks and flanges as they can be had for much cheaper than wood and you can buy a matched set with the exact size and profile for the block, the exact width and profile for the flange.

I've seen 3d moulds for hats and shoes on etsy so they are around