Q&A for How to Make a Felt Hat

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What kind of felt do I use and where can I get it?

Community Answer

Use wool felt--not synthetic. You should be able to buy this at any fabric store or even certain Walmart stores that carry fabrics.

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Question

Can I use felt blends, or does it have to be 100% wool?

Community Answer

I have made several hats (and a pair of shoes!) using this method, all with 100% synthetic felt. It works perfectly for the bowl of the hat--stretches like crazy! However, for the brim, use just a single layer of felt, stiffened with glue or starch or a sewn-in hat wire (ironing two wet, gluey layers together will not work with this felt; I think you need the stretching to get them to bond).

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Question

How long does it take to dry?

Community Answer

2 days is the perfect amount of time to let your felt hat dry.

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Question

Can I just use a Styrofoam head form?

Community Answer

You may be able to use one for the wool roving method, but keep in mind that most Styrofoam wig heads are much smaller than human heads. As such, your hat may end up too small. The shape will also be limited to the curved dome of the wig head.

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Question

What is a hat block?

Community Answer

A hat block is a wooden form used in hat making by milliners. It is shaped like the hat that you will be making, be it a top hat or a cloche.

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Question

If I want a pointed hat, do I need a pointed hat block?

Community Answer

Yes, but you can also felt a hat using a foam cone and wool roving. Alternatively, you can sew a felt sheet into a cone.

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Question

At about what level of experience will it take to make this hat?

Community Answer

The felt hood method will require a little more experience (including sewing) and supplies. The wool roving method can be done by a complete beginner. Most of the supplies should be readily available at a craft store.

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Question

How is the brim stitched to the side of the hat?

Community Answer

If you made the brim separately, stitch it on using an overcast stitch. This is where you pull the thread up through the bottom edge of the crown and down through the top edge of the brim. You'll then need to ad a hat band to hide the seam.

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Question

How do I make this hat have a rolled brim?

Community Answer

If you are using a felt hood, you will need a hat block with a rolled brim. In most cases, you will need to make the brim separately, then sew it into the hat once you are done. If you are using wool roving, you will need to attach some sort of rolled foam shape to the hat form, then felt the wool around that.

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