The Lone Ranger


This is our take on the classic Lone Ranger cowboy hat from the 1950s era western series, popularized by actor Clayton Moore.

  • Crown: 5″ inches
  • Brim: 4″
  • Color Shown: Bone
  • Available in all colors (see below)
  • Brim: hand rolled with kettle curl
  • Hatband: twisted leather
  • Comes with matching wind string
  • Hats ship in 6-8 weeks


Please choose your hat color. NOTE – Dyed Natural, Undyed Natural and CAMO are available in 20X and 100X only.


REQUIRED – Please select a shipping method.


If you are between hat sizes and know your head measurement enter it here, otherwise leave it blank.

Custom Made For

Let us know what you would like printed on the sweatband inside the hat? CUSTOM MADE FOR (20 character maximum please)

Production Notes

Anything special you’d like us to know about making your hat? Enter it here (like changing the hatband or modifying the brim shape).


Is included with your Hat Order.


Add soiling to your hat to give it that “worn” look.

Horse Hair Hat Bands

Add a quality horse hair hatband to any hat.

Cavalry Cords

Please select the Cavalry Cord of your choice for only $20!


The Lone Ranger

Our take on a classic tv series hat 

The Lone Ranger and Silver

Clayton Moore as the masked Ranger

The Lone Ranger was a popular radio serial and in 1949 it became a TV series for the new ABC Network and ran from 1949–1957. The original story was written in 1933 as a radio play for a station in Detroit by either George W. Trendle or main writer Fran Striker, or perhaps both.  The Lone Ranger soon became the highest-rated program on the young ABC network and its first real hit show, and earned an Emmy Award nomination in 1950.

When the series came to television, Clayton Moore landed the role of the masked Ranger and the producers decided on the cavalry charge from Rossini’s William Tell Overture as the series theme music.

Soon every small boy in North America was yelling HI-HO SILVER AWAY! in chorus with Moore and co-star Jay Silverheels (a Mohawk Indian from Ontario Canada) as they made history as the stars of the first Western written specifically for television. This was the Lone Ranger’s creed.

I believe…

  • That to have a friend, a man must be one.
  • That all men are created equal and that everyone has within himself the power to make this a better world.
  • That God put the firewood there, but that every man must gather and light it himself.
  • In being prepared physically, mentally, and morally to fight when necessary for what is right.
  • That a man should make the most of what equipment he has.
  • That ‘this government of the people, by the people, and for the people’ shall live always.
  • That men should live by the rule of what is best for the greatest number.
  • That sooner or later…somewhere…somehow…we must settle with the world and make payment for what we have taken.
  • That all things change but truth, and that truth alone, lives on forever.
  • In my Creator, my country, my fellow-man

In addition Trendle and Striker had these character guidelines for The Lone Ranger

  • The Lone Ranger was never to be seen without his mask or a disguise.
  • He was never captured or held for any length of time by lawmen, avoiding his being unmasked.
  • He always used perfect grammar and precise speech devoid of slang.
  • When he was forced to use guns, he never shot to kill, but to disarm his opponent.
  • He never wins against hopeless odds, rather realistically escapes to fight again another day
  • He never referrs to himself as the Lone Ranger, but would confirm people’s suspicion (either verbally or with one of his silver bullets) if they figured it out for themselves. The single exception was in the very first episode in which after fashioning his mask from cloth from his dead brother’s vest, he tells Tonto he will be known as the Lone Ranger.
  • His adversaries were usually groups whose power was such that large areas of land or whole towns were at stake. So even though The Lone Ranger offered his aid to individuals or small groups, the ultimate beneficiary of his actions was always that their part of the West improved and thus so did the country in general.
  • Adversaries were never other than American, to avoid criticism from minority groups…with a few exceptions.
  • Names of unsympathetic characters were carefully chosen, never consisting of two names if it could be avoided. More often than not, a single nickname was selected.
  • The Lone Ranger never drank or smoked; and saloon scenes were usually shown as cafes, with waiters and food instead of bartenders and liquor.
  • Criminals were never shown in enviable positions of wealth or power, and they were never successful or glamorous.
  • It was decided that the Ranger would only use silver bullets, to remind himself that life is precious and not to be thrown away.

The Lone Ranger story has become a uniquely American one and over time has reached iconic stature within our cowboy culture.  And with the William Tell Overture as its theme song, how could it lose!

Options for your Custom Hat

Add a Cavalry Cord $20.00


Cavalry Legend

Slouch Hats” worn by many Cavalry soldiers since the days of the American Civil War often include a colored cord that slides over the standard satin ribbon and bow hatband, which is referred to as a cord, braid, hobble, wrap, or acorn.

Guidelines for the use of the Cavalry Cord and colors were first outlined in 1890 in Circular 10, from the U.S. Army Adjutant General’s Office. Different colors are used to identify different branches of the service. The most common color, yellow, is worn by all enlisted Cavalry soldiers. Infantry wear white, Scarlet is for Artillery; Black; Chaplains/Staff, Black/Gold; Field Officer, Black/Silver; Warrant Officer.

The original reason for the acorns at the end of the cavalry cords is believed to have been to keep the cavalry man awake in the saddle, from the gentle drumming as the acorns bounced off the brim.

Battle/Combat Knots

There is a Cavalry legend that credits a non-com during the Civil War with tying knots in his cord to signify he’d been battle tested. The idea caught on and many units took to the practice on both sides. You can see an example on our Josey Wales Hat. Today cav cords can be knotted but it does not signify battle tested. Shoulder patches originated in the First World War to identify units, battalions or regiments. Combat patches (to signify a period of service in a war zone) started during the Second World War and continues to this day.


Add Trail Dust $55.00 – $95.00

trail dustMany 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 several years’ worth of trail dust – as if a hard living horse soldier had been wearing it.

We’ve got three different degrees of trail dust. Light (add $55.00) – medium (add $75.00), and heavy (add $95.00). Light would be what you see on our Boss Spearman medium would be like the dusting on the TRISTAN; and heavy trail dust looks like our Josey Wales.

This is a similar process that costume designers apply to hats in the movies and t. v. Looks authentic and yore friends will swear yer just got off a trail drive, or a hitch in the Horse Cavalry! You can add trail dust during the check out process – or request it when you call your order in.

Windstring/Stampede string

Add a Windstring/Stampede String $25.00

Our Windstring/Stampede String is made of heavy gauge Latigo lace {brown or black} and includes this complimenting leather slider. click image for a larger version

You can let us choose the right match for your hat or request brown or black latigo lace to go with your hand made cowboy hat.

Just add your request to the PRODUCTION NOTES as you build your hat.


Horsehair Hatbands $20.00 – $55.00

Add a quality horse hair hat band to any hat (ADD during checkout with the purchase of a hat – not sold separately). Can be worn on ANY hat just by sliding it over the satin ribbon and bow {as seen on the Wasey} or wear it alone.

Horse Hair Hat Bands

Captain Call

Captain Call a custom cowboy movie hat from Lonesome Dove (1989)

Bound Brim

Binding the brim edge with the same Grosgrain ribbon as the hat band, strengthens the edge, making it stiffer and allowing the brim shape to hold better.

A bound edge finishes the brim off nicely with rich looking detail. Most small brimed, or Town hats, have a bound edge.

The open crowned hat style was perhaps the most common crown style of the late 19th century and sold in the mail order catalogues of the day like, Sears-Roebuck, and the Hudson Bay Company.

Cowboys would crease and mold the crown, to add character to their hat, and make it easier to pick up. Decades later the hat companies started pre-creasing the cowboy hats in the most popular styles.

A bound Brim is more difficult to re-work or re-shape – but can be removed fairly easily.

Sundance Kid Custom Handmade Hat

Open Brim

Not as dressy or showy as a bound edge, this unfinished brim edge was much more common on working hats, cavalry and military hats.

An unfinished brim allows you to shape and mold it to your taste – or easily change the look in the future.

An Unfinished Brim is more for an everyday-do-yer-work type Cowboy Hat and likely the more common of the two finishes for a wide brimmed cowboy hat. It is also fairly easy to reshape the brim of a beaver/beaver blend cowboy hat with just a steam iron and a bit of patience.

Our Sundance Kid Custom Handmade Hat is a good illustration of the typical 19th century nondescript everday cowboy hat

** Shipping time is still 6-8 weeks on our custom hats **

Our Beaver Fur Felt Hat Bodies


All our hats are made with beaver fur felt which is dense and virtually waterproof. It consists of beaver and/or rabbit/hare fur blended with felt to produce a material that lasts 5-10 times longer than wool-felt.

A fine Beaver and Beaver blend fur-felt hat body holds its shape wonderfully and is the best material from which to manufacture hats.

As a general rule of thumb if a hat maker just 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.

In theory the higher the beaver content the higher the X factor – but unfortunately there is no standard within the hat making fraternity – and a lot of confusion. On the Internet few hat sellers tell you what their fur-felt is comprised of – and even seen straw hats promoted as 100X. The rough beaver hat bodies we use to make our cowboy hats are the best available and made in America.

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.
  • 20X is 50% beaver blend
  • 100X is pure 100% beaver fur felt

For an all weather hat you can’t beat a pure beaver cowboy hat. Light, stiff and fabulous looking it’ll shed what ever comes its way. And consider this: Beavers live in the water, rabbits in the dirt. 

  • GENERAL PRICING includes shipping in North America
    –     5X – 350.00      5% BEAVER HAT BODY
    –   20X – 480.00    50% BEAVER HAT BODY
    – 100X – 750.00  100% BEAVER HAT BODY
    – Prices for individual hat styles will vary
Dodge City Cowboy Movie Hat

Frontier or long haired fur-felt. The more rabbit or hare in the hat body the longer the fur felt will be. 5x will be the longest and 100x the shortest.

buffalo bill

A young buffalo bill cody


The Dodge City is shown in long hair Beaver fur-felt. Some call it SHAGGY some call it GRIZZLY, we prefer the name FRONTIER fur-felt to describe it, as this is what the very first beaver fur-felt would have been like.

Not as long as Buffalo Bill Cody’s hat seen here, but longer than today’s standard hat bodies.

You’ve likely seen this look before in a western movie. You can generally spot a long haired fur-felt in most of the westerns filmed in the 1930s and 40s. Errol Flynn wore it in several of his western movie’s like Dodge City.

FRONTIER FUR FELT has all the same characteristics as our fine, standard hat bodies – just a longer finish to the fur of the hat. You can request Frontier Fur Felt for any of our hats, simply by entering the request in the PRODUCTION NOTES.

Crown and Brim Measurements

Cowboy hats

The first steps in the crafting of a fine custom cowboy hat.

We make hand-made custom cowboy hats so the crown and brim measurements are pretty much redundant. 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 a different crown height or brim width, or if you want to tell us anything else about the making of your hat, just enter it into the PRODUCTION NOTES as you put together your hat order.

We can make up to 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 oversized hat body, which adds a little to the cost.

However the oversized brim can give you up to 50% more sun/bad weather protection, than a regular hat body.

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

A Note about Color

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

Light colors will reflect heat the best – while dark colors will retain the 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.

Please keep in mind we try to take our pictures with natural light – so differences between the same color reflects the difference in light when the picture was taken: Indoors, Outdoors, Sunny Day or Cloudy.

For the first 15-20 years cowboy hats were marketed – your choice of color was black and about 3 shades of brown.

Starting with the lightest and going to the darkest, here’s our colors



  • 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

True Old West Hats

Order your hat in 100X undyed, pure beaver fur-felt, and be one of the first to hearken back to an era in hat making a hundred and forty years ago. The first cowboy hats were made from 100% beaver fur-felt, natural and undyed, and unless the cowboy lost it or had it stolen – the hat lasted a lifetime. For an all weather hat – nothing beats a traditional western hat made from pure beaver fur – it’s what old west cowboys wore.









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Hat Sizes


You should know your hat size – just like you know your shoe size, pant or shirt size. 

If you are new to wearing sized hats it is always a good idea to visit your nearest mall and try on a few.  That way you know the fit and what your size is. 

  • Most hat sizes have only 3/8th of an inch difference between them, so just a 1/4 inch makes a big difference in the fit of a sized / fitted hat.
  • If you are a hat person, order your usual North American hat size. Our sizing is the same. The chart at right gives our standard hat sizing and the corresponding European sizes.
  • If you own a good hat, and can’t remember the size, turn the sweatband down and look at the underside. Most good hat makers will write key info on the back, including the hat size.
  • If you only know your hat size in cm, find the corresponding hat size at right to order, then add your size in cm to the production notes as you put your hat order together.

Refund Policy

We are making a hand made Custom Old West, or Western Movie Hat for you. You will keep it. 99% of orders everything will go smooth. In the odd situation where it doesn’t – we will make you happy, and get it right 100% of the time.

Our Most Common Hat Question

Q: I’m looking for a ____ Hat. I checked your product catalog and didn’t see it. Can you make it?
A: In most cases, yes. I’m sure you can appreciate it’s just not possible to show all the different variations of crowns and brims. If it’s made from fur-felt and you can supply us a good picture – yes we can make it.

Generally we already carry the same style of hat, we just shape it based on the photo or if it’s a movie hat we shape it from watching the movie and seeing the hat from all possible angles to get the look just so. We can do up to a 6″ (inch) high crown and a 5″ wide brim.   click for the rest of our hat facts



We recommend all customers who OWN a good hat, get a hat stretcher. It Is a small cost for a tool that will help keep ALL your hats fitting properly. As well, if you only wear your hat seldom; or have a number of hats you wear, you will find our wooden hat stretcher a valuable addition to maintaining the perfect shape of your custom cowboy hat. ~  Order a Hat Stretcher

Like all hat and leather products, our hat stands and hat stretchers are made in America.

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