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Whether you're new to hat styling or looking to refine your technique, our guide covers everything—from measuring your head for the perfect fit to adjusting the brim to match your style using steam. Whether you prefer a flat or curled brim, our step-by-step tutorial ensures you can customize your felt hat for both comfort and style.

The partnership between Mountain Khakis and American Hat Makers brings together two brands that share a passion for quality, adventure, and the great outdoors. By combining our expertise in outdoor apparel with their unparalleled craftsmanship in hat-making, we introduced the “Original Mountain Hat” that includes a limited-edition hand band partially constructed with the same canvas that we use in our Mountain Pant.

Wool & Felt Hats. Part 1: selecting your style and hat type.

The Difference Between Wool Packable Hats and Felt Western Style Hats

We’re excited to dive into the nuances between two popular types of headwear: wool packable hats and felt western style hats. Both styles offer unique benefits and cater to different needs and aesthetics. Understanding their differences can help you choose the perfect hat for your adventures.

Wool Packable Hats: 
Versatility and Convenience

1. Material and Construction Wool packable hats are crafted from high-quality wool, known for its durability, warmth, and natural water resistance. The wool fibers are flexible, allowing these hats to be easily folded and packed without losing their shape. This feature makes them an excellent choice for travelers and outdoor enthusiasts.

2. Portability One of the standout features of wool packable hats is their portability. Whether you’re hiking, camping, or embarking on a road trip, these hats can be conveniently stashed in your backpack or suitcase. They spring back into shape effortlessly, making them a reliable companion for any adventure.

3. Style and Functionality Wool packable hats come in various styles, including bucket hats, fedoras, and wide-brimmed options. Their versatile design makes them suitable for a range of activities, from casual outings to more rugged outdoor experiences. The wool material provides excellent insulation, keeping you warm in cooler climates while still being breathable enough for milder weather.

4. Care and Maintenance Maintaining a wool packable hat is straightforward. Spot cleaning with a damp cloth or a gentle brush can keep it looking fresh. Due to their natural resilience, these hats require minimal care, making them a practical choice for those on the go.

Felt Western Style Hats: 
Classic and Sturdy

1. Material and Craftsmanship Felt western style hats are typically made from a blend of wool and fur, resulting in a firm and structured finish. The felt material is dense and sturdy, offering superior protection from the elements. These hats are often handcrafted, showcasing meticulous attention to detail and quality.

2. Traditional Aesthetic Western style hats have a timeless appeal rooted in American history and culture. Known for their wide brims and distinctive creases, these hats evoke a sense of rugged individualism and frontier spirit. They are often adorned with decorative elements like leather bands, feathers, and conchos, adding to their unique charm.

3. Durability and Protection The robust construction of felt western hats provides excellent durability and protection. The wide brim shields your face and neck from the sun, while the dense felt material offers insulation against wind and cold. These features make western hats ideal for outdoor work, ranching, and equestrian activities.

4. Style Versatility While felt western hats are synonymous with cowboy culture, they have transcended their origins to become a versatile fashion statement. They can be dressed up or down, pairing well with both casual and formal attire. Whether you’re attending a festival, rodeo or a country-themed event, a western hat adds a touch of authenticity and style.


When deciding between a wool packable hat and a felt western style hat, consider your lifestyle and preferences. If you value portability and versatility, a wool packable hat is a great option. Its ability to be easily packed and maintained makes it perfect for travelers and outdoor enthusiasts. Mountain Khakis offers Pendleton hats from our retail locations in Lehi, Utah and Castle Rock, Colorado. We will also have some available on our website soon.

On the other hand, if you’re drawn to the classic, rugged aesthetic and need a hat that offers exceptional durability and protection, a felt western style hat is the way to go. Its traditional design and sturdy construction make it a timeless accessory that can withstand the elements. We have the Mountain Khakis “Original Mountain Hat” available in our Mountain Khakis retail stores and online at

Both wool packable hats and felt western style hats have their unique advantages, and Mountain Khakis offers a small selection of high-quality options in both categories. Explore our collection today to find the perfect hat that suits your needs and complements your style. Both styles work perfectly with our chino’s, work pants, flannels and vests.

Wool & Felt Hats. Part 2: Fitting your hat.

How to Measure Your Head for a Perfect Felt Hat Size

Here’s some advice to help you find the perfect fit for your felt hat. Ensuring your hat fits comfortably and looks great starts with an accurate head measurement. Follow these simple steps to measure your head for a felt hat and guarantee a perfect fit.


• Flexible measuring tape (cloth or plastic) 
• Mirror (optional) 
• A friend to assist (optional) 
• Notepad and pen for recording measurements 
• If you don't have a flexible measuring tape simply get a piece of string or a shoelace and then a tape measure or ruler.
Step-by-Step Guide:   
1. Position the Measuring Tape Correctly 
-Place the measuring tape around your head about 1/8 inch above your ears and across your mid-forehead. This is typically the widest part of your head where the hat will sit.
- Make sure the tape is level and straight, circling your head evenly.   

2. Ensure a Comfortable Fit 
-The measuring tape should be snug but not too tight. You want to ensure it’s comfortable enough to wear for extended periods without slipping. 
- If the tape feels too tight, adjust it slightly to ensure a comfortable fit.   

3. Read the Measurement 
- Look in the mirror or ask a friend to help you read the measurement where the end of the tape meets the rest. 
- Record this measurement in inches or centimeters for accuracy.   

4. Measure Twice for Accuracy 
- It’s a good practice to measure your head twice to ensure accuracy. Consistent measurements will help you find the best fitting hat. 
- Record the second measurement and compare it to the first. If there’s a discrepancy, measure again until you have a consistent result.  

5. Consult the Hat Sizing Chart 
- Refer to the Mountain Khakis hat sizing chart to find your perfect hat size. Different brands may have slightly different sizing, so always check the specific chart provided by the manufacturer. 
- If you’re between sizes, consider the type of fit you prefer. Some people prefer a slightly looser fit for comfort, while others prefer a snug fit to ensure the hat stays in place.

Wool & Felt Hats. Part 3: How to Size Your Felt Hat and Steam the Brim for a Perfect Fit

Our team at Mountain Khakis is excited to share some expert tips on how to size your felt hat to ensure a perfect fit and how to steam the brim to suit your personal style. Felt hats, sometimes called "beating your hat," offer timeless style and practicality, but achieving that perfect fit and look can require a bit of customization. Here’s your comprehensive guide on how to size your felt hat and steam the brim.


•  A kettle or pot for boiling water
•  A clean, dry cloth 
•  A flat surface for shaping

Adjusting Your Hat Size:


Hat Stretchers: Use a hat stretcher to gently stretch the hat. Insert the stretcher into the hat and turn the knob to widen the stretcher until it fits your head comfortably. Leave the stretcher in the hat overnight.  

Steam and Stretch: Another method involves steaming the hat and then wearing it while it’s still warm and slightly damp. This allows the felt to mold to the shape of your head.   


Hat Sizing Tape: Apply hat sizing tape or foam strips inside the sweatband. Place the strips evenly around the inside of the band to reduce the size. This method allows for easy adjustments and comfort. 

Sewing or Tucking: In some cases, you can sew a small fold in the sweatband or tuck in some fabric to make the hat fit more snugly.   Steaming the Brim for Personal Preference   Steaming the brim of your felt hat allows you to customize its shape to match your personal style. Here’s how you can do it:   


1. Boil Water: Fill a kettle or pot with water and bring it to a boil to produce steam. 

2. Steam the Brim: Hold the brim of your hat over the steam. Be careful to avoid burning yourself. The steam will make the felt pliable and easier to shape. 

3. Shape the Brim: While the felt is warm and soft, use your hands or a cloth to shape the brim to your desired style. You can create a flat brim, a curled brim, or any style that suits your preference. 

4. Set the Shape: Once you’ve shaped the brim to your liking, let the hat cool and dry completely. This will set the new shape.