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The Conversion Corral

T Jones

I'll Lock Up
Messages
6,795
Location
Central Ohio
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg
 
Last edited:
Messages
19,001
Location
Central California
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg

Looks great, Terry. I love felt that changes appearance in varying light.


Sent from my iPhone using Tapatalk Pro
 

Woodtroll

One Too Many
Messages
1,263
Location
Mtns. of SW Virginia
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg

I really like that ribbon; it looks like it has a blue undertone to it. Really nice job on the hat overall! I have come across a black Resistol 4x George Strait in 7-3/4 that I want to turn into a fedora for the rare funeral, etc. I would love to find a nice vintage midnight blue ribbon for it. Your post is very timely as it helps me envision how I want my hat to look. Thanks for all your informative posts!
 

T Jones

I'll Lock Up
Messages
6,795
Location
Central Ohio
I really like that ribbon; it looks like it has a blue undertone to it. Really nice job on the hat overall! I have come across a black Resistol 4x George Strait in 7-3/4 that I want to turn into a fedora for the rare funeral, etc. I would love to find a nice vintage midnight blue ribbon for it. Your post is very timely as it helps me envision how I want my hat to look. Thanks for all your informative posts!
Thank you buddy. I appreciate that. The ribbon with its bow was given to me by a fellow Lounger. It's of good quality and looks like it came off of a vintage hat. Seemed like a perfect fit for the one that I just converted.

...and you're very welcome. I'm glad it was helpful for you.
 
Last edited:

humanshoes

One Too Many
Messages
1,446
Location
Tennessee
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg
Very nice work there T. I think your ribbon skills are just getting better and better.
 

Daniele Tanto

I'll Lock Up
Messages
4,246
Location
Verona - Italia
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.
Terry your work is better and better! Bravo
 
Messages
10,847
Location
vancouver, canada
Just finished doing a quick fedora conversion from this '50s era Resistol 10 Homburg. A fellow Lounger gave this one to me. This is a super nice hat and the felt quality is amazing. I always wanted to try a Homburg but when I put it on, it was obvious that a Homburg just wasn't me. The hat is super clean inside and out and all original. I didn't take anything apart for this quickie conversion. The biggest skill set required for this one was care and patience...and having a fedora brim flange helps. Pretty easy if you take your time. I just ironed out the to flatten out the kettle curl and then ironed again on a brim flange. Unlike my other conversions, I didn't strip this one down. I wanted to leave all that was original to the hat intact. For the crown, all I did was to pop out the center dent to an open crown and then I misted it damp with water from a spray bottle, not soaking. From then on, it was easy. I recreased the crown to my preferred tear drop....

Before
Homburg-1.jpg


Homburg-16-A.jpg


Homburg-17-A.jpg


Homburg-18-A.jpg


Homburg-19-A.jpg


Homburg-20-A.jpg


On the head
Homburg-4-A.jpg


Homburg-9-A.jpg


Homburg-10-A.jpg
Amazing conversion. I would have bet against converting a homburg into a functioning and good looking fedora. As a homburg lover I did shed a tear for the loss!!......no to worry I will get over it!
 
Messages
18,443
Location
Nederland
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg
Another beautiful conversion, Terry. Great work! Lovely colours on the felt and I like that brushed finish.
 

RJR

Messages
10,620
Location
Iowa
Finally finished up this conversion. It started out as a size 6 3/4 6X Biltmore Western that was four sizes too small for me. I blocked this one up gradually with the last blocking done on the 'Rockwater' straight sided block. The hat started out with a tall 6 3/4 open crown and had a four inch brim width. After I reblocked it to a 7 1/4 hat size to fit me, I ended up with a 6 inch open crown and with a brim width that varied between 3 1/2 to 3 5/8 inches. So I still had more than enough brim to work with and I had a healthy open crown as well. Using the Rounding Jack that I got sometime back from Rick at Phoenix Hat Company I cut the brim down to 2 3/4. A Block and a Rounding Jack, handcrafted by two of our very own Lounge members, it doesn't get any better than that. Anyway, I also reworked the finish on this Biltmore and gave it a smooth and rich 'Brushed Velour' finish. The hat now has a 2 3/4 inches wide snap brim and is creased to my preferred tear drop. The open crown, as I said, is 6 inches, and as creased, is 4 3/4 at the pinch with a rake sloping to 4 1/4 in the back. The over all height of the crown as creased is 5 inches. I found a vintage 1 5/8 black ribbon and bow that I sewed on it to finish out the tall straight crown. The color on this hat has some interesting things going on. It looks to be a dark gray with brown undertones. Then at other times, it looks to be a dark brown. In any event, it's a nice color.

Before:
814357907481a7904f8393ff75c87bb1.jpg


On the 'Rockwater' block:
IMG-20181208-071204065.jpg


Completed:
Biltmore-Fedora-Hat-1-A.jpg


Biltmore-Fedora-Hat-2-A.jpg


Biltmore-Fedora-Hat-3-A.jpg


Biltmore-Fedora-Hat-4-A.jpg


This is closer to the true color of the hat:
Biltmore-Fedora-Hat-5-A.jpg
TJ,its been great watching as you've done more conversions.Your work has become very professional.
 
Messages
19,001
Location
Central California
I've had this hat for quite a while and havent worn it out yet, because of how dingy the brim binding/ ribbon were. Not too mention I always thought the cream on white was a little boring. So I nixed the old brim binding and ribbon and hand curled the brim. View attachment 149332 View attachment 149333 View attachment 149334 View attachment 149335

I liked it in its original condition, but your changes made it really pop! Such a rich warm hat deserves another lease at life.


Sent from my iPhone using Tapatalk Pro
 

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