Texas Hatters still uses the same basic methods of hat making that Marvin, Sr. learned as an apprentice hatter back in the 1920’s. Starting with unfinished blanks that we purchase from a felter all the way through the finishing that is done by hand in our little shop in Lockhart. These blanks look something like Jed Clampett’s hat, only without the holes.
After we measure a customer’s head, we discuss their choice of color, style and trim. Based on these factors, we then select the appropriate blank to begin a long, hands-on process. Although our family tradition of hat making goes back for three generations, most of the methods we apply are actually centuries old.
Each blank is steamed until soft and stretched over a wooden block appropriate for the customer's style and size. Once tied on, the blank is then wetted and ironed for several minutes. In the old days, hat makers would slick the fur down with mercury which poisoned them and made them insane (hence the saying,‘mad as a hatter’). We then give the hat a hair cut by applying sand paper. This sanding and ragging give the blank an almost polished look. This is especially so with the pure beaver. The same basic steps are then used for the brim on a wooden form called a flange.
After the blocking and flanging, we then cut the genuine leather sweatbands to size and sew them in by hand. Next, the satin lining and the ribbon trim is also sewn in by hand.
We also make several styles of custom hat bands including rattlesnake skin, leather and silver conchos, bone pipe beads, and Manny's own invention--the shotgun shell band. The shotgun shell uses the end caps of 10 gauges, 12 gauges and various other shotgun shells as conchos.
Another unique band is a hand woven one made by our close friend, Ruffin. She makes woven bands of fine wool, cotton or silk threads and offers many designs such as the shape of Texas, longhorns, thunderbirds and many geometric styles. Ruffin also makes many other hand woven articles in her shop, which is located next door to ours.
After all the trim, fancy or plain, each hat is then hand creased to the customer’s specifications. Of course, mail orders and now e-mail ordering makes things a little more complicated, but our custom treatment still goes into each and every hat we make.
Like Manny said over thirty years ago, “As modern as yesterday, with tomorrow’s ideas.” We blend traditional hat making methods with a modern approach to selling them.
