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I make my pirate hats from the highest quality wool felt. I use felt rather than leather as felt was the most commonly used material for making hats during the 17th and 18th centuries.
As to the actual process, let me say that you start by shearing a sheep for the wool and then... well... there are many closely guarded steps before reaching completion. Separating the wool fiber, making wool batting, turning that into felt, die bathing, boiling, blocking the hat, stretching, drying, stiffening, steaming, hand-shaping, steaming, drying, reshaping, drying, tacking, applying the oil/wax, curing.
Whew! it's a very time and labor-intensive process to produce a fine felt hat. Savvy? You'll be getting a true value to be sure.
Most of our hats can be made in 21, 22, 23, 24 and 25" circumferences, (unless otherwise specified). We use whole inches, no fractions of an inch. Instead of a commercial sizing chart, which vary from one Milliner (hat maker) to the next, we use the actual circumference measurement of our customer's head, by measuring around the crown of the head, just above the ears and resting on the brow.
One of the beautiful things about felt is that it can be stretched. If your hat is a bit too small you can easily steam it at your home and stretch it to fit your head. You can use the steam from a tea kettle to steam the inside and then quickly put it on your head. Detailed instructions provided upon request. If it is a bit big I suggest you wear a scarf or bandanna to complete your pirate look. So, choose the size that will most closely fit your actual head measurement (circumference in inches)..
Using a flexible tape measure, such as a tailor or seamstress might use. Start with one end in the middle of your brow (just above your eyebrows) and run the tape around your head until it meets up again. The tape should be snug, but not so tight as to leave a line on your head. Make note of that measurement as it is your head circumference.
If you don't have a flexible tape measuring device, you can use a long piece of string. Proceed with the same method as mentioned before and when done measure the string against a yardstick, ruler, or metal tape measure to obtain the circumference of your head.
Now, if you are planning on wewaring a Pirate Scarf, or Bandanna on your head, under your new pirate Hat make sure that you are wearing it when taking the measurement, or the size will be off.
If ordering an Acrylic Treated or Oil/Wax treated hat, I advise wearing a scarf or bandanna for comfort, as these hats are stiff and will reamin so for some time.
If you are ordering a Captain Jack's Pirate Hat please note:
Due to the large variety of styles, materials, colors, treatments, sizes and accessories, I do not stockpile or warehouse my hats. You are not getting a hat that was mass-produced in a factory overseas.
I make all of my hats, myself, by hand, to the specifications picked by the customer, using the highest quality materials and old world methods. You truly are purchasing a piece of living history.
There is usually about eight weeks of hat orders already in my production queue at any given time. My work is in hgih demand. I can assure you that the wait be worth it.
Yes! If you would like to purchase a hat for your special Pirate, but are unsure of the Specifics that he/ she would like ( Pirates can be a picky), or your special occassion is sooner than the time needed to make the hat, or you just want to pay for part of it... no problem. To get your Captain Jack Pirate Hat Gift Certificate in any amount send an E-mail to: firstname.lastname@example.org with the amount you'd like to gift and to whom it is gifted and we will send you payment instructions and a printable gift certificate jpeg. You simply "Print and Present". They can then contact us and we'll work out the specifics for their hat.