Blocking is one of the most essential techniques in the art of hatmaking. Whether you’re crafting a classic fedora or a modern custom design, mastering this skill is key to shaping your hat’s identity. In this guide, we’ll walk you through the steps to properly block a felt hat using traditional methods and reliable tools.

🪵 What You’ll Need

Before you begin, gather the following materials:

• A felt hat body (rabbit, wool, or beaver felt)
• A hat block in your desired crown shape
• A steam source (steamer or kettle)
• Rope or blocking cord
• Ironing canvas or pressing cloth
• Pins and flange (for brims, if shaping one)
• Hat brush and sponge

🔥 Step 1: Prepare the Felt

Gently steam the felt body until it becomes soft and malleable. Don’t oversaturate it—just enough to make it flexible.

🧰 Step 2: Position on the Block

Place the felt over the crown block, aligning the center. Stretch the felt gradually down the sides of the block to define the shape.

🔒 Step 3: Secure with Cord

Tie a blocking cord tightly around the base of the block’s crown to hold the shape. Smooth out any wrinkles as you tighten the felt.

✋ Step 4: Shape and Dry

Let the felt dry completely while on the block—ideally for 24 hours. Optionally, use pins or weights to refine curves and edges during drying.

✨ Step 5: Add Finishing Touches

After drying, trim excess felt, shape the brim (if applicable) using a brim flange, and brush the surface to bring out the felt’s texture.

🧠 Pro Tips

• Use consistent tension when pulling the felt to avoid uneven curves.
• Protect the felt with canvas or cloth when applying pressure or heat.
• Practice with wool felt before moving on to premium materials.

🧡 Final Thoughts

Hat blocking is a foundational skill for every hatmaker. Once mastered, it opens the door to endless design possibilities and custom shapes. With patience, quality tools, and proper technique, you can create hats that combine craftsmanship and character in every curve.