Alright folks, gather ’round! Today I’m gonna spill the beans on my latest DIY adventure: making a Tom Mix cowboy hat. You know, that iconic, larger-than-life hat? Yeah, that one. It was a wild ride, lemme tell ya, but totally worth it.
So, it all started with me binge-watching old Westerns. Tom Mix, with his flashy outfits and even flashier hat, just screamed “cool.” I figured, why not try and make one myself? How hard could it be, right? Famous last words…
First things first: research. I hit the internet, searching for images and descriptions of the hat. Figured out it’s got a tall crown, a wide, dramatically curved brim, and usually some fancy trim. Got a good idea of the shape and size I was aiming for.
Next up: materials. I knew I couldn’t just use any old felt. It needed to be stiff enough to hold its shape. I ended up ordering some heavy-duty wool felt online. Also grabbed some hat wire for the brim, some leather for the sweatband, and some ribbon for the trim. Oh, and a LOT of glue.
The actual construction? Well, that’s where things got interesting. I started with the crown. I made a pattern based on my head size and the desired height, cut out the felt, and started stitching. This was tricky, getting the shape just right, and keeping the seams clean. My first attempt? Let’s just say it looked more like a lopsided fez than a cowboy hat. Ripped it apart and started over. Second time was the charm…sort of.
Then came the brim. This was even tougher. I cut out the wide brim, inserted the hat wire around the edge to give it some stiffness, and then carefully stitched the felt over the wire. Bending the brim into that signature curve was a real pain. I used a heat gun to soften the felt and gradually shaped it. It took a lot of patience and some serious finger-burning, but I finally got it close to the right shape.
Attaching the brim to the crown was another challenge. Lots of glue, lots of pins, and a whole lotta hoping for the best. It wasn’t perfect, but it was holding together.
Now for the details! I added a leather sweatband on the inside for comfort. Then, I glued on a fancy ribbon around the base of the crown. I even added a few decorative conchos for extra flair. This is where I could really customize it and make it my own.
The finishing touch? Shaping the brim even more. I used steam from an iron to relax the felt and mold it into the final curve. This took a few tries, but I finally got the dramatic sweep I was looking for.
So, there you have it! My very own Tom Mix cowboy hat. It’s not perfect, by any means. There are a few wonky stitches and some slightly uneven curves. But hey, it’s handmade, and it’s got character! It was a tough project, for sure, but I learned a ton, and I’m super proud of the result. Now, if you’ll excuse me, I’m gonna go find my horse…