Picture of Reblocking A Vintage Felt Hat - Cheap & Easy
I love vintage hats - especially ones from the 20s to 40s. I recently became interested in hat making or millinery. And I was looking into buying some fur felt to make a hat. But, the local stores don't sell it and online it sells for more than I'm willing to spend at this point. So I started to think about the hats I have around my home, collecting dust - and realized I could transform them into something new. Most of the vintage hats I do have I bought at the Salvation Army thrift store for 59 cents and haven't worn them because most are too small and others are not my style. Doesn't make sense that they're sitting around with no use - so it's time to re-purpose them! The second problem I realized was that I didn't want to spend $100 to $200 on a hat block. This problem will also be cheap and easy to solve! So let's get started!
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Step 1: Materials Needed

Picture of Materials Needed
Materials for Felt Hat Re-blocking
  • Vintage Felt Hat
  • Styrofoam Mannequin Head
    • I bought one at Hobby Lobby for about $6
    • Please note: at Hobby Lobby they had ones with different head sizes - so bring measuring tape & try to get one that is about 1/2 inch bigger than your head size
  • Measuring Tape
  • Pins
  • Plastic Wrap & Aluminum Foil
  • Needle & Thick Thread if you need to sew any of the hat
    • If you need to sew through the felt, you'll need a special thread that is glazed but millinery thread is hard to find (you can get it online)
    • Or, I found at Hobby Lobby in the leather tooling section that they sold glazed or coated thread there - and that is what I used
  • *Optional: Steamer
  • *Optional: Modge Podge and Duck Tape
Bully_4_You1 month ago

Great tutorial! You might enjoy this video on using a hat to make your own new hat block.

ffcabral12 months ago

Awesome final result! :D I love those 20's fashion, and it's nothing you can't wear today. :D Retro has never been so in as in this new century.

(Just as a side note, you're very cute)

PitStoP1 year ago

Absolutely cute Holly..

HollyMann (author)  PitStoP1 year ago


You're welcome!! Keep it up, you're very talented...
studleylee1 year ago

I 2nd the Beautiful !!!


I love this new style, it's so classy! Beautiful job Holly!! :)

shazni1 year ago

this is lovely....I love your other hat too!

earz_cd1 year ago
I'd always wondered how to block hats. Thanks for sharing.
HollyMann (author)  earz_cd1 year ago

No problem :)

Stone_UFO1 year ago


HollyMann (author)  Stone_UFO1 year ago


Super Cute, Holly :)

HollyMann (author)  Tarun Upadhyaya1 year ago

thanks Tarun!!!