The Conversion Corral

[Scooterz]

Hat block. I wear 7 1/4 or 58 mostly. If I want a hat block to make an existing hat open crown with the sweat still on what size should I order? 7 1/8?

 

[T Jones]

Hat block. I wear 7 1/4 or 58 mostly. If I want a hat block to make an existing hat open crown with the sweat still on what size should I order? 7 1/8?

My opinion would be to just go ahead and get yourself an actual 7 1/4 block if that's the size you wear. Get an old hat you really don't wear much and practice taking it apart, reblocking it, and then putting everything back together. You can block a hat with the sweat in but it just doesn't look quite right.

 

[T Jones]

I recently posted this Bandera conversion in "The Other Open Roads" thread. Since then I had a change of plans with it. The hat originally started out as Bandera's version of the Open Road. It sported a 5 3/4 open crown with a 3 inch brim width. It definitely needed some work, and it was too small for me @ 7 1/8. In order to retain the original crown height and brim width I reblocked it on a 7 1/4 #51 block and only did some light cleaning on it so I could also retain its 'worn and lived in' look. I was successful but the block shape and the wide brim just didn't grow on me. So I took it apart apart again and reblocked it on my RA block and lowered my open crown height to 5 1/2 inches tall. My straight sided RA uses up a lot more material than my #51 and if I would have went with the full 5 3/4 crown height I wouldn't have had much brim to work with. So I readjusted my cord to get 5 1/2 inches and I was just barely able to get my preferred 2 5/8 brim width. With that, though, the original color of the hat which was hiding under the thin ribbon hat band crept up higher onto the crown. But I would rather live with it this way. I was able to lighten up the old shadow pretty much so its not too bad. The crown is creased, the brim is cut and reflanged, and I just recut the original brim binding to size and it's on the hat hat ready to be sewn on. Here's what I have so far...
Before:

First blocking on my #51:

Too much front to back crown taper and the brim was too wide to suit me.

Reblocked on my straight sided RA. The profile is completely vertical all around and much more to my satisfaction:

Off the RA and ready to trim the brim:

This is how close the trimming was even after lowering the crown height to 5 1/2 inches. This shows how much more material that my straight sided RA takes up than my #51 block:

Trimming on this part of the brim was right at the stitch holes where the brim binding was. It would be an easy fix if I was going to leave it raw edge but I'm putting the brim binding on it, so no big deal at all: the black stitching on the crown are the temporary basting stitches:

Notice the block differences and how much area the straight sided RA takes up over the #51:

Brim binding cut to fit and the ends sewn together: also, notice how far the old shadow under the thin ribbon crept up on the crown. I lightened it up pretty much by going over it with a yellow hat sponge:

Basting stitches to hold the binding in place while I sew on the permanent stitches:

Everything's almost ready. I'll have more when it's finished.

The open crown is 5 1/2 inches and is creased to my preferred tear drop, 4 3/4 at the pinch with a rake sloping to 4 inches in the back. The brim is 2 5/8 inches. Everything original to the hat will be reused, (just to add, the felt is awesome on this hat).


My thanks again to Suited Cowboy who gifted this hat to me.

 

[Blare]

I recently posted this Bandera conversion in "The Other Open Roads" thread. Since then I had a change of plans with it. The hat originally started out as Bandera's version of the Open Road. It sported a 5 3/4 open crown with a 3 inch brim width. It definitely needed some work, and it was too small for me @ 7 1/8. In order to retain the original crown height and brim width I reblocked it on a 7 1/4 #51 block and only did some light cleaning on it so I could also retain its 'worn and lived in' look. I was successful but the block shape and the wide brim just didn't grow on me. So I took it apart apart again and reblocked it on my RA block and lowered my open crown height to 5 1/2 inches tall. My straight sided RA uses up a lot more material than my #51 and if I would have went with the full 5 3/4 crown height I wouldn't have had much brim to work with. So I readjusted my cord to get 5 1/2 inches and I was just barely able to get my preferred 2 5/8 brim width. With that, though, the original color of the hat which was hiding under the thin ribbon hat band crept up higher onto the crown. But I would rather live with it this way. I was able to lighten up the old shadow pretty much so its not too bad. The crown is creased, the brim is cut and reflanged, and I just recut the original brim binding to size and it's on the hat hat ready to be sewn on. Here's what I have so far...
Before:

First blocking on my #51:

Too much front to back crown taper and the brim was too wide to suit me.

Reblocked on my straight sided RA. The profile is completely vertical all around and much more to my satisfaction:

Off the RA and ready to trim the brim:

This is how close the trimming was even after lowering the crown height to 5 1/2 inches. This shows how much more material that my straight sided RA takes up than my #51 block:

Trimming on this part of the brim was right at the stitch holes where brim binding was. It would have been an easy fix if I was going to leave it raw edge but I'm putting the brim binding on it, so no big deal at all: the black stitching on the crown is the temporary basting stitches:

Notice the block differences and how much area the straight sided RA takes up over the #51:

Brim binding cut to fit and the ends sewn together: also, notice how far the old shadow under the thin ribbon crept up on the crown. I lighted it up pretty much by going over it with a yellow hat sponge:

Basting stitches to hold the binding in place while I sew on the permanent stitches:

Everything's almost ready. I'll have more when it's finished.

The open crown is 5 1/2 inches and is creased to my preferred tear drop, 4 3/4 at the pinch with a rake sloping to 4 inches in the back. The brim is 2 5/8 inches. Everything original to the hat will be reused.

Wonderful job Terry.

 

[T Jones]

Wonderful job Terry.

Thank you Blare!

 

[1967Cougar390]

I recently posted this Bandera conversion in "The Other Open Roads" thread. Since then I had a change of plans with it. The hat originally started out as Bandera's version of the Open Road. It sported a 5 3/4 open crown with a 3 inch brim width. It definitely needed some work, and it was too small for me @ 7 1/8. In order to retain the original crown height and brim width I reblocked it on a 7 1/4 #51 block and only did some light cleaning on it so I could also retain its 'worn and lived in' look. I was successful but the block shape and the wide brim just didn't grow on me. So I took it apart apart again and reblocked it on my RA block and lowered my open crown height to 5 1/2 inches tall. My straight sided RA uses up a lot more material than my #51 and if I would have went with the full 5 3/4 crown height I wouldn't have had much brim to work with. So I readjusted my cord to get 5 1/2 inches and I was just barely able to get my preferred 2 5/8 brim width. With that, though, the original color of the hat which was hiding under the thin ribbon hat band crept up higher onto the crown. But I would rather live with it this way. I was able to lighten up the old shadow pretty much so its not too bad. The crown is creased, the brim is cut and reflanged, and I just recut the original brim binding to size and it's on the hat hat ready to be sewn on. Here's what I have so far...
Before:

First blocking on my #51:

Too much front to back crown taper and the brim was too wide to suit me.

Reblocked on my straight sided RA. The profile is completely vertical all around and much more to my satisfaction:

Off the RA and ready to trim the brim:

This is how close the trimming was even after lowering the crown height to 5 1/2 inches. This shows how much more material that my straight sided RA takes up than my #51 block:

Trimming on this part of the brim was right at the stitch holes where brim binding was. It would have been an easy fix if I was going to leave it raw edge but I'm putting the brim binding on it, so no big deal at all: the black stitching on the crown is the temporary basting stitches:

Notice the block differences and how much area the straight sided RA takes up over the #51:

Brim binding cut to fit and the ends sewn together: also, notice how far the old shadow under the thin ribbon crept up on the crown. I lighted it up pretty much by going over it with a yellow hat sponge:

Basting stitches to hold the binding in place while I sew on the permanent stitches:

Everything's almost ready. I'll have more when it's finished.

The open crown is 5 1/2 inches and is creased to my preferred tear drop, 4 3/4 at the pinch with a rake sloping to 4 inches in the back. The brim is 2 5/8 inches. Everything original to the hat will be reused.

Great work as usual Terry!

Steven

 

[T Jones]

Great work as usual Terry!

Steven

Thank you buddy!

 

[1967Cougar390]

My Mickey Mouse inspired Akubra Stylemaster. I did this simple conversion for my family trip to Disney World.

Have a safe and blessed evening.

Steven

 

[Blare]

My Mickey Mouse inspired Akubra Stylemaster. I did this simple conversion for my family trip to Disney World.

View attachment 327339

Have a safe and blessed evening.

Steven

Great idea

 

[Randall Renshaw]

Newest conversion finished today.
A Don Williams Stetson clone.
Did this one for my oldest brother.
He LOVES Don’s songs. Knows em all by heart. I like the “Gentle Giant” a lot, myself.
I used a size 7 late 60s 3X Stetson and disassembled it. Craig is my size, so 7 1/4. Blocked, flanged, shaped and distressed. Added a lightly bleached brown ribbon and dyed a Calvary style new gold two cord hatband with acorns to a darker old looking color.
As you can tell, I went with the felt color of Don’s later hats. His earlier ones were a bit darker.
Could’ve distressed it further, like Don’s, but Craig wants to do it naturally, which won’t take him long, since he’s a hard worker and a true woodsman. Don’s song, “I’m Just a Country Boy” suits him well.

We’ll all miss the smooth singin’ man and his songs.

Sewed in one of my signature sweatbands.

 

[Randall Renshaw]

My Mickey Mouse inspired Akubra Stylemaster. I did this simple conversion for my family trip to Disney World.

View attachment 327339

Have a safe and blessed evening.

Steven

Hahahah! Good’n!

 

[Randall Renshaw]

I recently posted this Bandera conversion in "The Other Open Roads" thread. Since then I had a change of plans with it. The hat originally started out as Bandera's version of the Open Road. It sported a 5 3/4 open crown with a 3 inch brim width. It definitely needed some work, and it was too small for me @ 7 1/8. In order to retain the original crown height and brim width I reblocked it on a 7 1/4 #51 block and only did some light cleaning on it so I could also retain its 'worn and lived in' look. I was successful but the block shape and the wide brim just didn't grow on me. So I took it apart apart again and reblocked it on my RA block and lowered my open crown height to 5 1/2 inches tall. My straight sided RA uses up a lot more material than my #51 and if I would have went with the full 5 3/4 crown height I wouldn't have had much brim to work with. So I readjusted my cord to get 5 1/2 inches and I was just barely able to get my preferred 2 5/8 brim width. With that, though, the original color of the hat which was hiding under the thin ribbon hat band crept up higher onto the crown. But I would rather live with it this way. I was able to lighten up the old shadow pretty much so its not too bad. The crown is creased, the brim is cut and reflanged, and I just recut the original brim binding to size and it's on the hat hat ready to be sewn on. Here's what I have so far...
Before:

First blocking on my #51:

Too much front to back crown taper and the brim was too wide to suit me.

Reblocked on my straight sided RA. The profile is completely vertical all around and much more to my satisfaction:

Off the RA and ready to trim the brim:

This is how close the trimming was even after lowering the crown height to 5 1/2 inches. This shows how much more material that my straight sided RA takes up than my #51 block:

Trimming on this part of the brim was right at the stitch holes where the brim binding was. It would be an easy fix if I was going to leave it raw edge but I'm putting the brim binding on it, so no big deal at all: the black stitching on the crown are the temporary basting stitches:

Notice the block differences and how much area the straight sided RA takes up over the #51:

Brim binding cut to fit and the ends sewn together: also, notice how far the old shadow under the thin ribbon crept up on the crown. I lightened it up pretty much by going over it with a yellow hat sponge:

Basting stitches to hold the binding in place while I sew on the permanent stitches:

Everything's almost ready. I'll have more when it's finished.

The open crown is 5 1/2 inches and is creased to my preferred tear drop, 4 3/4 at the pinch with a rake sloping to 4 inches in the back. The brim is 2 5/8 inches. Everything original to the hat will be reused, (just to add, the felt is awesome on this hat).


My thanks again to Suited Cowboy who gifted this hat to me.

Looks awesome as usual, Terry!
So, with this one how many hats will you have made? You do fine work.


I got a new straight sided block from Randal Alan about a month ago.
Liked it so good I ended up coating my old one with bondo and sanded it down to my specs.

Works so much better, now. Looks good after painting it Mopar Plum Crazy Purple; since I already had that color.

 

[Blare]

Fantastic job Randall. I’m sure he will love it.

 

[Randall Renshaw]

Fantastic job Randall. I’m sure he will love it.

Thanks, Joe!
I’ve since cut the brim back a bit. Was too wide. Made a big aesthetic difference.
Was almost 3 1/4 now it’s at 3” like Don’s.

 

[Steve1857]

Nice conversion, Randall. Don Williams was one of my favourite country singers back in the day. I remember buying one of his lps in England in the late 70s

View attachment 350868 Newest conversion finished today.
A Don Williams Stetson clone.
Did this one for my oldest brother.
He LOVES Don’s songs. Knows em all by heart. I like the “Gentle Giant” a lot, myself.
I used a size 7 late 60s 3X Stetson and disassembled it. Craig is my size, so 7 1/4. Blocked, flanged, shaped and distressed. Added a lightly bleached brown ribbon and dyed a Calvary style new gold two cord hatband with acorns to a darker old looking color.
As you can tell, I went with the felt color of Don’s later hats. His earlier ones were a bit darker.
Could’ve distressed it further, like Don’s, but Craig wants to do it naturally, which won’t take him long, since he’s a hard worker and a true woodsman. Don’s song, “I’m Just a Country Boy” suits him well.

We’ll all miss the smooth singin’ man and his songs.

View attachment 350865 View attachment 350869 View attachment 350866

Sewed in one of my signature sweatbands. View attachment 350871

 

[Randall Renshaw]

Thanks, Steve!
Yeah, Don was the man! We’re losing all the great ones. Willie’s still kickin’ and he and my Dad is the same age.
Dad will be 88 in December, but can’t play the guitar for arthritis. How Willie still does tours I don’t know.

 

[T Jones]

View attachment 350868 Newest conversion finished today.
A Don Williams Stetson clone.
Did this one for my oldest brother.
He LOVES Don’s songs. Knows em all by heart. I like the “Gentle Giant” a lot, myself.
I used a size 7 late 60s 3X Stetson and disassembled it. Craig is my size, so 7 1/4. Blocked, flanged, shaped and distressed. Added a lightly bleached brown ribbon and dyed a Calvary style new gold two cord hatband with acorns to a darker old looking color.
As you can tell, I went with the felt color of Don’s later hats. His earlier ones were a bit darker.
Could’ve distressed it further, like Don’s, but Craig wants to do it naturally, which won’t take him long, since he’s a hard worker and a true woodsman. Don’s song, “I’m Just a Country Boy” suits him well.

We’ll all miss the smooth singin’ man and his songs.

View attachment 350865 View attachment 350869 View attachment 350866

Sewed in one of my signature sweatbands. View attachment 350871

Looks great buddy! Nice job! I like that style of Western, something of a throwback to the old TV Westerns of the '50s and '60s. Just my style and just my size too!

I did one similar last year with this '50s era 3X Stetson. It started out as a size 7 and was crushed up and badly stained with sweat and dirt. The Lounger who gave it to me said it had a story to tell. It was definitely worn for work. I liked the distressed look so I cleaned it up just enough to get nasty off of it....and I blocked it up two sizes to fit me. I even kept the original 3ply ribbon and brim binding.

 

[T Jones]

Looks awesome as usual, Terry!
So, with this one how many hats will you have made? You do fine work.


I got a new straight sided block from Randal Alan about a month ago.
Liked it so good I ended up coating my old one with bondo and sanded it down to my specs. View attachment 350877 View attachment 350879 Works so much better, now. Looks good after painting it Mopar Plum Crazy Purple; since I already had that color.

Thanks buddy. I've done quite a few with that RA block. It gives a nice straight full profile. Here's the Bandera completed. I forgot to post a picture the hat after I finished it.

That's pretty neat, though, what you did with yours. I like that MOPAR plumb color! It looks great! I take it that you're a fellow MOPAR fan?

 

[Randall Renshaw]

Looks great buddy! Nice job! I like that style of Western, something of a throwback to the old TV Westerns of the '50s and '60s. Just my style and just my size too!

I did one similar last year with this '50s era 3X Stetson. It started out as a size 7 and was crushed up and badly stained with sweat and dirt. The Lounger who gave it to me said it had a story to tell. It was definitely worn for work. I liked the distressed look so I cleaned it up just enough to get nasty off of it....and I blocked it up two sizes to fit me. I even kept the original 3ply ribbon and brim binding.

Looks awesome, Terry! Still don’t know how you get those huge paws to do such perfect, intricate, tedious work.
No doubt that you do, though.
The new Randal Alan block I got had sides with absolutely zero taper front, back or sides. That’s great when doing C-crowns, but for a single crease it can only cause reverse taper because the single crease pushes out the front and rear. So I ended up belt sanding a small taper toward the top. It’s a 60cm block at the bottom and now 59.4 at the top.
Not much, but it helps. My block also had a sharp shoulder where the break of the dome started from the sides.
Didn’t translate well to a crown so I sanded the sharpness off, too. Still a nice shoulder, just not a creased transition. Randal’s new composite material he uses don’t like to belt sand very well, but I finally had my way with it. Wants to melt while sanding, but can be done.
On the old Randal block that I used bondo on it now has completely square sides, but tapered front and back with a difference of a full 1.3 cm taper from bottom to top. It’s a 59 cm block. Shaping it that way makes it perfect for fedora crowns having either a single or diamond crease.
Produces 90 degree sides and square front and backs.

 

[Randall Renshaw]

Thanks buddy. I've done quite a few with that RA block. It gives a nice straight full profile. Here's the Bandera completed. I forgot to post a picture the hat after I finished it.

That's pretty neat, though, what you did with yours. I like that MOPAR plumb color! It looks great! I take it that you're a fellow MOPAR fan?

Great job on the Bandera !
Nice Ram Jam! So...Do ya call it “Black Betty”?
I’m a definite Mopar man who’s, at this time, driving a Ford pickup as a work truck.
My last pickup was a Dodge Duelly 4x4 with the Cummins. Loved it.
Got this Ford cheap, so I’ll drive it awhile. I lean towards Mopar trucks and Chevy cars, but buy whatever brand and model that happens to made well at the time I’m buying and whatever I can get at a bargain.
Here’s my “full size” Mopar muscle car. It’s the reason I had plenty of left over spray paint.