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!

Step 1: 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
<p>Great job! You did a terrific job with reshaping the old hat, and making your own block! My mother made her first block in the 60's from a huge metal can covered with foil and tape! Later she bought a balsa wood block, which I have today. www.hatshapers.com makes hat forms and blocks from heat resistant plastic that are much more affordable than wood. </p><p>You might be interested in the website and community Hat Talk and How2Hats. Working with wool is addictive!</p>
<p>Thank you SO much! I really appreciate it. I am going to check out the site and community. :) Thanks for sharing the story about your mom. That's awesome you have a balsa block..I wanted to buy one before but haven't yet! I will check out hatshapers - I have been on there before, a long time ago!!!</p>
<p>Beautiful form! I have always been curious as to how felt is reshaped into such cool organic shapes. Thank you for posting</p>
<p>Great tutorial! You might enjoy this video on using a hat to make your own new hat block.</p><p>http://youtu.be/WZwC1D5KVLY</p>
<p>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.</p><p>(Just as a side note, you're very cute)</p>
<p>Absolutely cute Holly..</p>
You're welcome!! Keep it up, you're very talented...
<p>I 2nd the Beautiful !!!</p>
<p>I love this new style, it's so classy! Beautiful job Holly!! :)</p>
<p>this is lovely....I love your other hat too!</p>
I'd always wondered how to block hats. Thanks for sharing.
<p>No problem :)</p>
<p>Super Cute, Holly :)</p>
<p>thanks Tarun!!!</p>

About This Instructable




Bio: Army Vet. I love learning & being creative.
More by HollyMann:Gluten Free Crepes Recipe Unique Puff Pull-Through Braid Large Leather Pencil Case for Art Supplies & More 
Add instructable to: