Mini Cowboy hat

  • Advertise with us
Project by jeffthewoodwacker posted 12-11-2011 03:56 AM 2777 views 2 times favorited 11 comments Add to Favorites Watch

Mini sized cowboy hat turned from freshly cut ambrosia maple. Hat is 4 1/4” tall and 8” wide at the brim. I turn these to a little less than 3/32 inch thick. To keep track of the thickness I turn the lights out in the shop and place a light directly behind the cut – when the glow becomes a yellow/orange color it is thin enough. When the inside of the hat is turned I reverse chuck on a jam chuck with an LED light. Sanding is done in steps as I work through the brim and into the inside of the crown. This hat weighs less than 2 ounces! Finish is several coats of hand rubbed danish oil. Hats are put on a bending jig after turning to get the brim shape. One day when I have time I will attempt to do a blog on the process. Turning time is around two hours total. Full size hats take longer.

-- Those that say it can't be done should not interrupt those who are doing it.

11 comments so far

View Woodbridge's profile


3548 posts in 2441 days

#1 posted 12-11-2011 04:01 AM

I’ve seen a few turned cowboy hats since participating on LJs and it never ceases to amaze me how you can turn a hunk of wood into a hat. They look so real. Wow. The grain and colouring on your hat is extremely nice.

-- Peter, Woodbridge, Ontario

View terrilynne's profile


836 posts in 2916 days

#2 posted 12-11-2011 04:34 AM

Beautiful wood and nice hat.

-- Terri, Rocky Mountain High Colorado!

View Jim Jakosh's profile

Jim Jakosh

20589 posts in 3128 days

#3 posted 12-11-2011 05:29 AM

Wow! What a gorgeous hat!!.

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View KoryK's profile


229 posts in 2712 days

#4 posted 12-11-2011 05:31 AM

That is so neat, the way you can gauge your thicknes. I’m sure that took some trial an error. Great job!

-- If you not making sawdust, your probably wasting your time. Kory

View MShort's profile


1790 posts in 3441 days

#5 posted 12-11-2011 06:05 AM

Very nice. I think I would end up with funnel trying to make one.

-- Mike, Missouri --- “A positive life can not happen with a negative mind.” ---

View Karson's profile


35125 posts in 4423 days

#6 posted 12-11-2011 06:23 AM

Great looking hat.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View rance's profile


4258 posts in 3183 days

#7 posted 12-11-2011 06:37 AM

Nice hat Jeff. I can’t bring myself to turn a full sized hat but a mini might be worth tackling. What part do you turn first and how do you hold it in the lathe? What’s the progression?

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View ed220's profile


624 posts in 3416 days

#8 posted 12-11-2011 06:37 AM

Very nice hat. Great job !

View jeffthewoodwacker's profile


603 posts in 3827 days

#9 posted 12-11-2011 05:26 PM

Rance, I start with the hat mounted on a screw chuck and turn the rough shape of the outside of the hat. A tenon is created in what will be the top of the hat brim and the tenon is then held in a chuck. I refine the outside shape of the hat and sand the outside through all the grits. The brim of the hat is turned from the outside edge to the inside of the crown of the hat in stages. I use a light directly behind where I am turning to determine if the thickness is correct. As each stage of the brim is finished I sand it through all the grits before moving onto the next part of the brim. This continues all the way up through the crown of the hat. Once the entire inside of the hat is turned and sanded I reverse chuck the hat on a wooden jamb chuck that has a light installed in the center. The top of the hat is finished and the tenon is completely turned away.

-- Those that say it can't be done should not interrupt those who are doing it.

View rance's profile


4258 posts in 3183 days

#10 posted 12-11-2011 08:58 PM

That should do it Jeff. Thanks for the info.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View kiefer's profile


5619 posts in 2690 days

#11 posted 12-12-2011 04:52 AM

That’s a hat I be proud to hang on my rack.
Absolute fantastic job and so real looking .
Here in Alberta we still wear those felt once and I will put the word out that there are wooden one’s LOL


-- Kiefer

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics