Sundance Kid Cowboy Hat

Sundance Kid Cowboy Hat


Sundance Kid Cowboy Hat – Our take on a classic western movie 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
  • 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


Please choose your hat color. NOTE – Natural is available in 20X and 100X only. Camo is available in 100X only.


REQUIRED – Please select a shipping method.

Size of Last Hat and Brand

Please enter the Brand of the last hat you wore that fit you well.

Custom Made For

Let us know what you would like printed on the sweatband inside the hat? CUSTOM MADE FOR (20 character maximum please). No Charge.

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.


Add a stampede string (windstring) to your hat. Comes with a leather slider and we choose the color to complement your hat color. Comes installed. Only $25!

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!

UPGRADE to one of our Century Hat Bodies (Natural and darker colors only)

Upgrade to any of our incredible Century Hats (Dark Colors only). Mink and Chinchilla hats come with a hard can hat case and a hat brush. These hat bodies are special order only.


Sundance Kid Cowboy Hat

Sundance Kid Cowboy Hat – Our take on a classic Western Movie Hat 

Robert Redford bears a remarkable resemblance to the historical Harry Longabaugh and it certainly didn’t hurt his chances of landing the plum role, of the Sundance Kid, opposite Paul Newman.  Steve McQueen or Marlon Brando were the movie studio’s choice to play the Sundance Kid. But Paul Newman and the director; George Roy Hill had their way and Redford was cast.

The movie was a smash, making Redford a star, and the movie song by Bacharach and David, won the academy award for best song: Raindrops keep Falling on my Head. Butch Cassidy and the Sundance Kid is easy to like, very entertaining, and follows what history knows of Butch, Sundance, and Etta closely.

Like many of th cowboy hats seen in the movie, the Sundance Kid cowboy hat is a pretty nondescript style that would have been a good representation of the type of hat worn by many cowboys back in the old west of the later part of the 19th century.

The opening scene below was edited to make Sundance’s fast draw even faster. Watch carefully when the Sundance Kid draws and shoots the gunbelt off the other Poker Player. You will see Butch stutter step across the background! Regardless this is still one of the great opening scenes in western film history, and sets the tone for the entire film.

See all of our Old West Hats here.

The Cowboy Hat defines the wearer

A traditional cowboy prized his hat above all things – with good reason. It was often worth a month or two’s wages – and that made it very expensive. The cowboy likely spent hours personalizing the hat with creases to the crown and molding the brim – that made it his.

A 19th century cowboy would go to hell and back to retrieve a misplaced old west hat and it was seldom further than an arm’s length away.

Old Fashion Quality
You won’t find these western hats at your nearest mall. Many of the brim shapes or crowns may look familiar, may even be the same.  But they are poor imitations or cookie-cutter designs.  Mass produced and available virtually anywhere. Don’t follow the herd – strike out on your own with a classic custom western hat from The Last Best West.

The Last Best Cowboy Hat
We start with the best fur-felt hat body available – made in the USA.  We fashion as fine a hand-made western hat as you can find anywhere, for any price.

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 Lt. Col. Kilgore, Our Sabre River hat has a medium dusting 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

Additional information

Beaver Fur-Felt

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Our Beaver Fur Felt Hat Bodies


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 gold standard from which to manufacture fine working 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 it is hard to beat a pure beaver cowboy hat. Light, stiff and fabulous looking its the gold standard for an all weather hat, and will shed what ever comes its way. And consider this: Beavers and minks live in the water, rabbits in the dirt. 

    – 5X – 355.00 5% BEAVER HAT BODY
    – 20X – 495.00 50% BEAVER HAT BODY
    – 100X – 795.00 Pure BEAVER HAT BODY |
    prices for individual hat styles will vary
    any hat style, any size – same price

    – 100X – 1190.00  PURE BEAVER BELLY HAT BODY
    – 100X – 1590.00  MINK HAT BODY
    – 100X – 2790.00 CHINCHILLA HAT BODY

Dodge City Cowboy Movie Hat

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.

NOTE: 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.

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

We often 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.

Cowboy hats

One of the first steps in the crafting of a 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
  • GUN BARREL GREY, a bluey grey metal color
  • 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.








2 reviews for Sundance Kid Cowboy Hat

  1. Bill Abell

    From: bill abell
    Sent: July 5, 2019 9:07 PM
    To: Service at The Last Best West

    This hat (Sundance Kid) is really awesome you should be proud for making it  it’s hard to get good quality regardless how much you spend but I’m quite pleased  this hat has become part of me thank you

  2. Dave Meyer

    From: Dave Meyer
    Sent: November 2, 2019 4:47 PM
    To: The Last Best West
    Subject: Re: [The Last Best West]: SHIPPED! Meyer order

    [Dave ordered our Sundance Kid hat!]

    … I just took my first look at the hat, it’s beautiful. I’ll have to stretch it just a bit but that’s to be expected. Again,  appreciate the great customer service you provided…Thanks again!! Dave

Only logged in customers who have purchased this product may leave a review.

Hat Sizes


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

soft tape measure

If you wish to confirm your hat size by measuring your head

  • You’ll need a friend, and a soft tape measure to measure with. You know – the type the fella uses to measure your trouser inseam.

  • Look straight ahead and have your helper measure your head. Using the soft tape – they should measure over your hair, just above your ears, and a half inch above your eye brows.

  • Make sure the tape is slightly slack – but not loose. You should be able to feel the tape but it should not be tight – or the fit will be as well! Measure twice – to be sure. BUT ONCE AGAIN NEVER MEASURE TIGHT.

  • Match your head measurement to the closest corresponding hat size and enter it in the production notes section of the order.


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. 

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 embossed on the sweatband inside the hat. Your name embossed on the sweatband tells the World you have a custom hat!

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 stretchers are made in America.

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