Custom Cowboy Hats

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Custom Cowboy Hats

CUSTOM COWBOY HATS

It’s the last thing you take off, and the first thing that’s noticed!

Our hand-made hats ship in 6-8 weeks.

Made to order. Made to last. Made in America.

Purchase one of our fine beaver-blend hand made cowboy hats and you will receive the same quality and workmanship that is worn by more than a dozen of the world’s premier rodeo cowboys riding today. Production Companies, Marshals, Sheriffs, Musicians, Writers, Cartoonists, Artists, Athletes, Soldiers, and lots of every day folk love our hats, and we hope you will as well. Testimonials

100X Mink Cowboy Hat Century GradeComing Soon!

We are excited to be introducing  a premier line of hat bodies in BEAVER BELLY, MINK, and CHINCHILLA. These are the most luxurious hat bodies in the world and are available only in 100x. If you’d like to be notified when we premier these spectacular hat bodies, email [email protected]

Shown here is the hat style worn by Hugh Jackman as Drover, in the film epic; Australia. Made from 100X natural mink this is the absolute finest in all weather hat wear. Minks are semi-aquatic and their fur is oily and even more dense than beaver fur. Making the minks fur extremely soft and very desirable for milliners, and sought after by hat people.

We have all kinds of hats from classic western styles from the 19th century to reproductions of your favorite hats from the cowboy movies of bygone years. Click for our hat and product catalog

The cowboy hat has become inseparable with a certain way of life and moral conduct recognized around the world as North America’s contribution to World Culture.

You should find our website easy to get all the information you need when ordering, simply by clicking on the tabs 1/2 way down each product page. There you will find our hat colors, leather colors, options and instructions for hat sizing, measuring yourself for a gun belt, and other useful information about our products. 

Option Tabs

Crown and Brim Measurements

The hats you see online are our standard hats, which have specific crown heights and brim widths to maximize the look of that particular style or hat design. If you wish to change the crown or brim enter any changes in the Production Notes section as you build your hat.

The largest hat we can make has a six (6″) inch crown and a five (5″) brim.

Any hat with a brim width of more than 4 inches we must start with an over sized hat body, which adds a little to the cost. Most of our cowboy hats have a crown height between 5 and 6 inches and a brim width of 3 1/2 to 4 inches.

Hat styles with a wider brim include The Wasey, Quigley, Everett Hitch, Desperado, Blue Duck, Hoss, Blondie, Little J, The Dunson, Last of the Dogmen, Wild Bill, all our B-Movie hats, and many of our Custom Rodeo Hats

A cowboy hat will protect your head from the weather, eyes from the sun, and will help prevent sun stroke.

You’ve worn the rest now own the best!

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What does custom mean?

Cowboy hat sweatband

HATS
We allow clients to switch hatbands between hat styles, and request different crown and brim dimensions. As well you get your name stenciled on the sweatband inside the hat. Your name stenciled on the sweatband tells the World you have a custom hat!

WHEN YOU GET YOUR HAT

Your hat comes with a couple of  felt stays that slide up under the sweat band should the hat be slightly loose. They act as a shim. And should the hat be a touch snug the hat stretcher that comes with it will solve that. And if worse comes to worse, we will get the hat back and re-block it to the right size. We make sure that all clients get a hat that fits. more on hat size

Questions and quote requests please e-mail  [email protected]

In 2012 we supplied a pure beaver hat for a door prize at a Super Bowl party held by Americans for the coalition troops in Afghanistan. We received this thoughtful gift in return. Patrol flown flag and commemorative plaque. Thanks Master Sergeant! Hooo Raaa

Jimi Hendrix musicians hat

Jimi Hendrix musicians hat

It has been our honor and pleasure to make our fine working hats for Peace Officers, State Troopers, Sheriffs, Marshals, Officers, Soldiers and Security Contractors.

So rest assured our Last Best Cowboy Hats will stand up to any and all rain, snow, and scorching sun you may have to put it through. We make working hats for working people, and our hats are dye fast and will not fail you when the going gets tough, and the weather turns from bad to worse.

And if you are looking for something to dazzle the masses, our hats are end of the line fine for that as well. For our clients we have duplicated everything from a Jimi Hendrix hat to an old west classic worn by Luke Short or Tom Horntestimonials

Our last best cowboy hats can be seen in (wax) museums, commercials, ad campaigns, and film. Read more on our in the news page

ABOUT OUR BEAVER FUR-FELT HAT BODIES

  • Beaver Fur Felt is dense and virtually waterproof. It consists of beaver and rabbit/hare fur blended with felt to produce a material that lasts 5-10 times longer than wool-felt. What makes it so exceptional is the beaver hair has a barb on the end like a fish hook, and as a consequence the beaver fur in the hat body meshes together, making it strong and rigid.

  • A fine Beaver and Beaver blend fur-felt hat can be re-blocked and shaped numerous times, with just a steam iron and some patience. Beaver fur-felt is one of the finest materials from which to manufacture the best custom cowboy hats.

  • As a general rule of thumb if a hat maker only describes their hat bodies as fur-felt, chances are it’s rabbit or hare. Hat makers who use beaver fur-felt are proud of it and will state so. We sell 3 quality beaver blends of fine western hats – 5X, 20X and 100X. 5X is a blend of about 5% beaver with rabbit and felt. Our 20X is 50% beaver and our 100X is pure 100% beaver fur-felt.

  • Like all hat makers we buy rough hat bodies from a factory, and then work our magic. The rough hat bodies we use to make our cowboy and dress hats are the best available and made in the USA.

  • GENERAL PRICING includes shipping in North America

    –     5X – 380.00      5% BEAVER HAT BODY

    –   20X – 510.00    50% BEAVER HAT BODY

    – 100X – 785.00  100% BEAVER HAT BODY

    – Prices for individual hat styles will vary

  • For an all weather hat it’s hard to beat a pure beaver cowboy hat. Beaver fur-felt is the gold standard for hat makers. Light, stiff and fabulous looking it’ll shed whatever comes its way. And consider this: Beavers live in the water, rabbits in the dirt. So for an all weather hat what would you rather have it made from?

Cowboy Hat colors

A Note about Color

Colors for our custom cowboy hats

Color variances caused by individual computer monitors is beyond our control.

Light colors will reflect heat the best – while dark colors will retain heat the most – with black being the worst for staying hot (black absorbs sunlight). However black is the most formal color so bowlers and top hats were generally black or dark gray. For the first 15-20 years cowboy hats were marketed – your choice of color was black and about 3 shades of brown.

Please keep in mind we do our best to take pictures with good color representations of our hats and leather. But there will be differences between the same color and that reflects the difference in light when the picture was taken: Indoors, Outdoors, Sunny Day or Cloudy.

Starting with the lightest and going to the darkest, here’s our colors.
Click on the color to see a hat example.

BONE :: SILVER MIST :: SILVER BELLY :: SAND :: DYED NATURAL :: SAHARA
UNDYED NATURAL  :: CAMOUFLAGE :: PECAN :: BUCKSKIN  :: WHISKEY :: RUST
CHOCOLATE :: MOSS GREEN :: NAVY :: GRANITE :: CHARCOAL :: BLACK CHERRY :: BLACK

COLOR DESCRIPTION

    • BONE dirty white, the color of a bleached bone

    • SILVER MIST very pale gray

    • SILVER BELLY another pastel color this is a grayee-brown

    • SAND a very pale yellow. Beach sand color

    • GRANITE a light to medium light gray

    • CHARCOAL a dark gray

    • BLACK CHERRY has an apple red undertone. Only noticeable in bright light

    • BLACK the most popular hat color

    • SAHARA mid brown a shade lighter than natural

    • NATURAL rich mid brown the color of a beaver pelt

    • PECAN A browny-green. KHAKI

    • RUST a dark browny-red, the deep color of a rusty metal pipe

    • BUCKSKIN a bright yellowy brown

    • WHISKEY dark amber like a shot of whiskey

    • MOSS GREEN a dark rich green

    • CHOCOLATE a dark brown

    • NAVY BLUE dark blue

COLOR PALETTES

EARTH TONES
BONE :: SILVER BELLY :: SAND :: DYED NATURAL :: SAHARA
UNDYED NATURAL  :: CAMOUFLAGE :: PECAN :: WHISKEY
RUST
:: MOSS GREEN :: CHOCOLATE :: BUCKSKIN 

PASTEL COLORS
BONE : SILVER MIST : SILVER BELLY : SAND

WARM COLORS
WHISKEY : RUST : MOSS GREEN
CHOCOLATE : BLACK CHERRY : NAVY

GREYS
SILVER MIST : GRANITECHARCOAL : BLACK

COLORS NOT SHOWN IN THE GROUP PICTURE
CHARCOAL :: BLACK CHERRY :: BUCKSKIN :: NAVY BLUE

LIGHT COLORS :: DARK COLORS :: GREYS AND BLACK


ABOUT US :: SHIPPING POLICIES :: RETURN POLICIES :: CONTACT US

Order with confidence; all hat details are confirmed via email within a BUSINESS day of your Custom Cowboy Hatsorder being placed.

Questions and quote requests please e-mail to service @ thelastbestwest .com/

Our standard delivery is 6-8 weeks for our hand made hats.

Overseas buyers please read this 


HATBANDS

All our hatbands that ship with our hats are stitched in place, and are easily removed with a couple of snips. And the beauty of our line of replacement hand-made hatbands is they simply slide over the existing satin ribbon and bow, to give a new and different look to your hat. One hat 2 looks!

Trail Dust

Josey Wales cowboy movie hatMany custom cowboy hat customers have been requesting that we dirty up their new hats to make them look trail worn. Pictured is a dusty Tristan – our Tristan hat with a couple of years worth of soiling to give it that Buckaroo lived in look.

We’ve got three different degrees of trail dust. Light (add $55.00) – medium (add $75.00), and heavy (add $95.00).

Trail dust is applied by hand so no 2 dusting’s are the same! And light colors will always show the trail dust better than dark!

Light would be what you see on our BOSS SPEARMAN, medium would be like the dusting on the TRISTAN, and heavy trail dust looks similar to our JOSEY WALES.

This is a similar process that costume designers apply to hats in the movies and TV. Looks authentic and your friends will swear you just got off a trail drive, or a hitch in the Horse Cavalry! You can add trail dust during the check out process.

custom cowboy hats

1898 BOW
This was one of the most common bow styles of the 19th century. If you prefer this bow style for any of our hats, just request it in the NOTES section of your order.

LADIES BOW
Back in the 19th century and the first 4 decades of the 20th century, when hats were a very common part of every day dress, women’s hats had the bow on the right hand side. If you want the bow on the right – request it in the NOTES section of your order.

Answers to our most common hat questions

Made to Order. Made to Last. Made in America by the Cowboys of  The Last Best West


  • Samuel Jones Movie Hat

    $360.00$750.00
    Our version of the Samuel Jones Movie Hat - from The Missing The Samuel Jones Movie Hat is the one worn by Tommy Lee Jones, as Samuel Jones, a  white man turned Apache, who returns to his estranged daughter in time to try and rescue his grand-daughter from slave traders. Like the character there is nothing fancy about this hat, a simple open crowned cowboy hat with a bit of a pencil roll.
    • CROWN HEIGHT: 5" INCHES Open
    • BRIM: 4" 1/2" Pencil roll, with a gentle hand roll - Bound.
    • Color: Pecan
    • Hatband: Satin Ribbon with bow, with matching bound edge.
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
  • There Will Be Blood Hat

    $355.00$760.00
    Our version of the Daniel Plainview hat  We show our There Will Be Blood Hat with a contrasting hat band and bound edge; Movie Hat is a Pecan color with a matching SRB and bound edge. If you wish a different color hat band and bound edge, from your hat color, please enter it in the PRODUCTION NOTES section as you build your hat below. Similar crown styles Wasey, Byron McCelroy, Conagher 250_white_filials
    • Crown 5 inches
    • Brim: 3"
    • Hatband: 1 1/2" grosgrain ribbon and bow.
    • Crown: modified Sagebrush
    • Brim: pencill rolled with a slight hand roll
    • Color Shown: Undyed natural with a chocolate brown grosgrain ribbon, bow, and bound edge.
    • Hats ship in 6-8 weeks
  • The classic Homburg dress hat from the 19th Century Our take on the Mister Howard Homburg Dress Hat is an authentic Milliner design from the 19th century and was worn all over the world. Hat is worn by Brad Pitt as Jesse James in the western character study, The Assassination of Jesse James by the Coward Robert Ford
    • CROWN: 4 1/2 inches
    • BRIM: 3 inches
    • Hatband: 1 1/2" inch satin ribbon with bow.
    • Crown: Center Crease
    • Brim: Kettle Curl Bound
    • Available in ALL Colors
    • Color shown: Black
    • Hat ships in 6-8 weeks

  • Josey Wales Cowboy Hat

    $355.00$760.00
    Josey Wales style Cowboy hat - our take on this classic western movie hat Our version of the Josey Wales Cowboy Hat has a bound brim edge and a satin ribbon and bow for the hat band, with the optional cav cord over it. You can choose white, yellow, black, red, or 2 styles of officer for your cavalry cord. Shown in sand with optional heavy trail dust, and unsoiled in silver belly.
    • CROWN:4 1/2 inches
    • BRIM: 4"
    • Crown: Slight front pinch, Pecan top.
    • Brim: 1/2" Kettle Curl Bound
    • Hatband: 1" satin ribbon with optional Cavalry Cord
    • Color: Bone with optional heavy soiling And unsoiled in our classic silver belly color
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
    • Hatband not sold separately
  • Thing Movie Hat

    $390.00$810.00
    Our take on Kurt Russell's hat from the Thing. The Thing Movie Hat - This 4 dent military style has the largest dimensions we can make. A 6 inch crown with a 5" brim. If you'd like the brim flatter on the sides, just put that request in the Production Notes box below.
    • Crown: 6 inches
    • Brim: 5"
    • Crown: 4 Dent Military
    • Color Shown: Chocolate
    • Brim: Hand Shaped -open
    • Hatband: Wrapped 3/4" distressed leather strapping/windstring
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
  • Rigby Reardon

    $335.00$750.00
    Rigby Reardon Fedora - our version of the hat from Dead Men Don’t Wear Plaid. {1982} Dead Men Don’t Wear Plaid may be the cleverest movie in the history of film. This was the first film that cut in classic film scenes and legendary film stars into the plot and dialogue of the story.

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    • Crown: 5"
    • Brim 2 3/4" inches
    • Hatband: 2" Grosgrain ribbon and bow.
    • Crown: Fedora
    • Brim: Snap Brim, hand shaped Open
    • Color: Black
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks

  • Augustus Custom Handmade Hat

    $335.00$750.00
    augustus custom handmade hat style from the classic mini-series, Lonesome Dove (1989) Loveable old Ranger Augustus McCrae is the scalawag that keeps the Hat Creek Cattle Company loose and is a great counter balance to the salty Woodrow Call.  This style of old west crown with it's 3 pinch cavalry creasing was first called the "Tom Mix" after the early movie star, and then became known as "The Gus" crease because of  Lonesome Dove. This is a great look for both men and women! 250_white_filials
    • CROWN: 6 inches
    • BRIM: 4"
    • Crown: Modified 3 pinch cavalry
    • Brim: Hand worked and rolled
    • Hatband: Custom 1/2" leather twist
    • Color shown: Sand
    • hats ship in 6-8 weeks
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
  • Captain Call Handmade Hat

    $335.00$750.00
    A custom cowboy movie hat from Lonesome Dove (1989) Our take on the hat style worn by Tommy Lee Jones The Tommy Lee Jones cowboy hat from Lonesome Dove. The Captain Call Handmade Hat is like the character simple, unrefined, and basic. A classic Boss of the Plains with a heavy dip front and back on the bound brim.
    • Crown: 6 inches
    • Brim: 4"
    • Crown: Open - uncreased
    • Brim: Bound Hand shaped dipped front and back.
    • Hatband: 1" grosgrain ribbon with bow
    • Color shown: Black in 20X fur-felt
    • hats ship in 6-8 weeks.
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
    • Hatband not sold separately
  • Jake Spoon Lonesome Dove Hat

    $365.00$790.00
    Jake Spoon Lonesome Dove Hat - our take on the Robert Urich hat style from the mini-series (1989) This is a big dang hat – befitting the self-centered character deftly played by Robert Urich. Everything is about Jake and this thoughtless, arrogant, gambler makes a bad choice and ends up riding with the wrong crew. We start with an over-sized hat body to make the Jake Spoon.
    • Crown: 6" inches 4 dent military
    • Brim: 4 3/4 inches Kettle curled/hand rolled with bound edge
    • Hatband: Matching 1" Satin Ribbon/Bow
    • Color: Sahara
    • hats ship in 6-8 weeks
    • Personalized with your name inside the crown
    • Hatband not sold separately
    • Hats ship in 6-8 weeks

  • Big Heat Handmade Fedora

    $335.00$750.00
    Big Heat Handmade Fedora Hat - our take on Glenn Ford's fedora from The Big Heat. {1953} The Big Heat features great fedoras in almost every scene, and this is our take on the Dave Bannion hat.
    • Crown: 5" inches
    • Brim 2 3/4"
    • Hatband: 2" Black grosgrain ribbon and bow.
    • Crown: Fedora
    • Brim: Hand shaped snap brim, with front dip. Bound
    • Color: Granite
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
    • Hatband not sold separately
  • Butch Cassidy Cowboy Hat

    $370.00$750.00
    Our take on the Butch Cassidy Cowboy Hat - Paul Newman was one of the great actors of his generation and by the time he made Butch Cassidy...he was a big box office attraction and a darling of the critics. This is our version of the Butch Cassidy cowboy hat Newman wears in many scenes of this classic 1960s western film. 
    • Crown: 5 inches
    • Brim: 3 inches
    • Color: Whiskey
    • Crown: Telescope
    • Brim: Open Gentle hand roll
    • Hatband: Custom 1" embossed green suede.
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
  • Sundance Kid Cowboy Hat

    $370.00$750.00
    Our take on a classic western movie hat Sundance Kid Cowboy Hat - the hat worn by Robert Redford in 1969s, Butch Cassidy and the Sundance Kid.  This hat is pretty nondescript and is a good representation of the type of hat that would have been seen in the later half of the 19th century on many of the cowboys riding through the west.
    • Crown: 4 1/4" inches Telescope
    • Brim: 3 1/4 inches open with a gentle hand-roll
    • Color: Chocolate with light trail dust
    • Hatband: 1/2" distressed brown leather
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks

  • Cimarron Custom Movie Hat

    $335.00$750.00
    Cimarron Custom Movie Hat - Our version of the Yancey Cravat hat from the 1931 best picture winner. This is a very versatile hat style. The crown is a modified tycoon with a big kettle curl and roll to the brim. Musicians seem to favor our Cimarron Custom Movie Hat, and it looks great with a good suit of clothes. Performers hat, Dress Hat, or wear it on the range and impress the critters. What more do you need in a hat!
    • Crown: 4 1/2" inches Modified Tycoon
    • Brim: 3 1/2" Kettle Curl, hand rolled
    • Color Shown: bone
    • Hatband: 1" Grosgrain ribbon and bow.
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
  • Pinkerton Custom Town Hat

    $335.00$750.00
     Pinkerton Custom Town Hat hand made by the last best west During the Victorian Era {1837-1901} this short top hat was one of the more common hat styles worn throughout the English speaking world. We have made the Pinkerton Custom Town Hat with everything from a 3 1/4" crown (musician) to a full 6 inch top hat. If you have specific crown and brim measurements, just enter them in the PRODUCTION NOTES below, as you build your hat order. This style also looks dynamite on women, and as a STEAM PUNK hat!
    • Crown: 4" inches Texas Straight
    • Brim: 2 3/4" Hand Shaped Bound
    • Hatband: 1 1/2" satin with bow.
    • Color: Black
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks

  • Big Heat Handmade Fedora

    $335.00$750.00
    Big Heat Handmade Fedora Hat - our take on Glenn Ford's fedora from The Big Heat. {1953} The Big Heat features great fedoras in almost every scene, and this is our take on the Dave Bannion hat.
    • Crown: 5" inches
    • Brim 2 3/4"
    • Hatband: 2" Black grosgrain ribbon and bow.
    • Crown: Fedora
    • Brim: Hand shaped snap brim, with front dip. Bound
    • Color: Granite
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks
    • Hatband not sold separately
  • Fred Dobbs

    $335.00$750.00
    The Fred Dobbs fedora - our take on the hat from the classic  Bogart film, - Treasure of the Sierra Madre. (1948) One of our all time favorite films this hat is a new version of the ratty top that Bogart sports as the living-on-the-edge adventurer, Fred C. Dobbs. A classic fedora from the last best west shown here in our rich charcoal color.
    • CROWN: 5 inches
    • BRIM: 2 3/4 inches
    • Hatband: 1" Grosgrain ribbon and bow.
    • Crown: Fedora
    • Brim: Snap Brim, hand shaped
    • Color shown: Charcoal
    • Personalized with your name inside the crown
    • Hats ship in 6-8 weeks

Complete hat and product index