Custom Cowboy Hats


Our hand-made hats ship in 12-14 weeks and our custom cowboy leather in 3-5 weeks.


1957 a timeless cowboy hat designCustom Cowboy Hat – The 1957

Custom Cowboy Hat – The 1957.  A classic cowboy hat style

Richard Boone wore one. So did Dean Martin. Richard Benjamin the star of the original West World movie wore one. All variations of the same classic cowboy hat style

Fact is you could tune into just about any tv show or western film from the 1950s and 1960s and see one. So we thought this was a good representation of this cowboy hat style, we are calling 1957.

Whitey from Godless custom hatAnd it is still popular today with the Whitey character from the NETFLIX series Godless sporting one.

The front crown pinch might be wider or narrower, the brim might have less or more curl. But they are just a variation of this timeless cowboy hat shape.

Introductory savings of 20% for our new hat. The 1957.
Discount will automatically show in your shopping cart. Limited time only

In addition to the new hat we have added two new hat bands to our Replacement Hat Band Collection

Our Sand Pebbles Military Hat Band is 3/4 inch wide, dyed heavy leather hat band. With your choice of military insignia and black or white stone spots. Shown in our unusual burnt coffee brown and classic royal blue colors.

Our classic Rim Fire leather hat band will tell the world that you are a lover of the West. Five nickle slotted conchos on dark brown or black leather 1/2 inch wide. and tied off at the back with a wooden slider.

The Last Best Cowboy Hat

To all you fine folks who are visiting us for the first time – HOWDY! 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

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

Sent: December 25, 2022 12:20 PM
Subject: (7) My Last Best Hat – YouTube [Col. Yorke Cavalry Hat]

Thought you might get a smile out of this best, sj

What does custom mean?

Cowboy hat sweatband

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 embossed on the sweatband tells the World you have a custom hat!

1898 Bow for a Cowboy Hat1898 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.

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

Hat Liner

Our galloping cowboy logo is on all our last best west hat liners.

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.

Hats are all hand made so hat and brim measurements are all approximate. 

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.

Cowboy Hat Colors

Tom Horn Cowboy hat

We constantly get asked if we can make an EXACT replica of a particular hat. The answer is no. Realistically no one can. Our quality hats are made, formed, shaped by hand, not a machine. When anything is made by hand there are bound to be slight variations. Not even the original master hatter could make one EXACTLY the same. We make our version of that 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? quote? e-mail [email protected]


After 20 years of making some of the finest custom hats available it’s time to thin the herd! We’re clearing out many of our showroom and prototype hats, that we have accumulated over the years.

Some have been lightly worn, in TV series and movies, like Wynonna Earp, and Hell On Wheels. Most are brand new, or like new and have been marked down up to a 150 dollars.

The hats vary in quality from 5X to 20X and 100X. All sizes and colors are as stated and there are no changes, modifications or substitutions.

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 museums, commercials, ad campaigns, TV and film. Read more on our in the news page


  • 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 – 395.00      5% BEAVER HAT BODY–   20X – 525.00    50% BEAVER HAT BODY– 100X – 815.00  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 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

    • 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

    • GUN BARREL GREY a blue grey similar to blued metal









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/

Overseas buyers please read this 


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 Josey Wales – our Josey Wales hat with a couple of years worth of soiling added, to give it that horse soldier lived in look. Does not affect the longevity of the hat, just the 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.

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

  • Josey Wales Cowboy Hat

    Josey Wales Cowboy hat - our take on this classic western movie hat Our version of the Josey Wales 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
    • Hatband not sold separately
  • Thing Movie Hat

    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

  • Big Heat Handmade Fedora

    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
    • Hatband not sold separately
  • Cimarron Custom Movie Hat

    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
    • Musician Favorite

Complete hat and product index


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