Hat Making Tool: Rounding Jack Prototype #2, Hat Brim Cutter

The DeCou (dee-coo) Rounding Jack

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Update for 6-16-2008: This Rounding Jack Serial Number #2008-02 has been Sold and is headed to Suffolk, VA USA.

Customer Testimony Printed with Permission:

Hey Mark,

“I just received the rounding jack and tolliker and wanted to say thanks for getting them off to me so fast. I used the rounding jack earlier this evening and did not quite get it perfect the first time. This was my fault due to inexperience with the tool. I did not keep the jack tight enough against the hat as I made the second turn. The brim did come out perfect, after a little sanding was done to correct my error. I’m sure, now that I’ve been through it once, the next one that I trim will be perfect. I have to say that the tools look just as good in person as they did in the photos.”

“Thanks again, so much. I don’t think I’ll ever be able to sell these tools. Besides being useful, they are simply too beautiful to part with.”

Bruce

Here is Stoney's posting in The Fedora Lounge Forum

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The current version that I am building and selling will cut brims from 1-1/4” up to 8.0” in size.

Look here for some examples of the final design:

1. Maple Rounding Jack
2. Brainpan Hat Shop Rounding Jack
3. Steve Delk's Adventurebilt Rounding Jack
4. Marc Kitter's Adventurebilt Rounding Jack

If you are interested in a Rounding Jack, or other hatmaking tool, please email me at:
mark@decoustudio.com

www.decoustudio.com

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Original Project Story:

Recently, after posting Tollikers and Puller Downers here on Lumberjocks, I was asked by a hatmaker whether I would make an up-to-date version of an old antique tool called the ”Rounding Jack,” which is used to cut the brim of a hat, such as a Fedora style, or Western Style Hat, to the proper width.

I looked at several examples of old Rounding Jacks, and figured out what didn’t work in their design after 100 years of shop use, and also what features one had over the other.

I have a mechanical engineering degree, and so I approach projects, like this one, from a practical engineering standpoint. Couple that training with a lifetime of woodworking, and I can build tools like this. When I say “lifetime” of woodworking, I’m not blowing smoke…...my dad was a woodshop teacher and is still a master woodworker, and so I have had a workbench and woodworking tools for as long as I remember, literally. Some folks say “lifetime” and don’t really mean it….....I mean it. (Thanks Dad!)

The key problems I discovered with the antique examples were:
1) The wood was too soft of a species, and wouldn’t hold up to the wear it gets in use over the years
2) The components made of wood were too narrow, and thin, and broke easily from normal use.
3) The old blades that fit them were obsolete and difficult to find, or sharpen
4) The old blades run up and down vertically, which does not offer a nice slicing motion of the felt
5) The cutting capacity was too short, and needed to have been built for bigger brims
6) The cutting path should be counterclockwise for a right handed maker
7) The blade needed to adjust in and out easily
8) The blade needed a plate guard under it so that the table top wasn’t scored while cutting the brim, and the brim could be “held” in place as the blade cut the material.

and some others problems I found, but you get the gist of what I was after.

I tried to solve all of the problems in my design, using Walnut, but other woods such as Birch, or Maple, could just as easily be used.

I can’t seem to be happy with making something “practical-but-ugly”, so I also tried to make the proportions pleasing, and the over all appearance consistent with what you would expect from a solo-artisan’s shop, where each item is still hand crafted.

So, if you are a hat tool collector, or a hat maker, and would like to know more about purchasing a Rounding Jack from me, please send me an email for more information.

please email me at:

mark@decoustudio.com

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Here is a photo showing the Prototype model (left) and the Production Model (right).

Features

The DeCou Rounding Jack includes an adjustable brass crown curve, utility knife blade, angled cutting, large cutting capacity, wide posture to allow smooth and flat operation, mortise and tenon joinery reinforced with screws, hardwood (walnut in this case) and a heavy duty brass plate on the bottom.

If you do not want the adjustable crown curve, I can save you some money by not charging you for that work. Send me an email for the complete pricing breakdown with options.

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Customer Ordering NOTE:

To keep the Pricing down on these tools, I used a small metal ruler for the sizing guage. Some have told me that they liked the look of the hand carved sizing guage like I did on the original prototype design.

So, if you are ordering a Rounding Jack from me, and you really want the look of the hand carved guage, just let me know and I can do that for you.

Note: In my mind, tools should be as beautiful as they are functional. To that end, each tool receives an inlayed abalone dot as a “signature.” I can also use engraved brass plates, inlayed scrimshaw artwork, or other details that tool collectors will like.

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Bottom Plate Guard:

I use a strong brass plate 0.032” in thickness, that covers the blade in all of it’s possible settings. The brass guard fits under the hat brim while cutting, and you push down on the cutter onto your work table as you cut around the hat.

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Blade Type & Direction of Cut:

I have used a very inexpensive, but high quality “Stanely” (made in the USA) utility knife blade for the working part of this Rounding Jack. These blades are available in any store. If you are ordering a Rounding Jack, and you have a different type of blade that you prefer to use, that is fine, just tell me, and I can redesign your cutter for your needs.

Also, this photo shows a COUNTERCLOCKWISE cutting path. If you are a CLOCKWISE hatter, then just let me know and I can make your Rounding Jack to fit your needs.

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For a Guage Pointer, I have used a brass point that is calibrated to the guage ruler. After you use this a few times, you will gain the confidence to never have to use a tape measure again. Just loosen the thumb screws, slide the apparatus to your cut size, and retighten the thumb screws. And then make a hat. It’s that simple.

Still, if your are the type of person that wears a belt and suspenders, you can always measure the blade opening with a tape measure if you are just in that habit.

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Artisan Hat Tools by Mark DeCou Studio
(Do you want to see More? Just follow these links):

Rounding Jack – The Collector-Series Model w/ a Brass Blade Holder:

1. “Coming Soon”, Progress Photos posted here

Rounding Jack – The Economy-Priced Hobbyist-Hatter Model:

1. Walnut Rounding Jack w/ Bench Top Display Stand
2. Walnut Rounding Jack w/ Laser Engraved Ruler

Rounding Jacks – Custom Built:

1. “Custom Laser Engraved Rounding Jack for Charlie @ Gladdhatter”: coming soon, please check back
2. Rounding Jack, Maple Wood on a Walnut Bench-Top Display Stand
3. Custom Rounding Jack w/ Scrimshaw for the Brainpan Hat Shop in Sumner, WA
4. Custom Rounding Jack w/ Scrimshaw for Steve Delk's Adventurebilt Hat Co.
5. Custom Rounding Jack w/ Scrimshaw for Marc Kitter's Adventurebilt Hat Co.
6. Custom Rounding Jack w/ Scrimshaw for Pyrate Trading Co.
7. Custom Rounding Jack w/ Scrimshaw for the Infamous Hatman Jack at Wichita Hat Works
8. Custom Rounding Jack Laser Engraved for the Inaaya Hat Co.
9. Custom Rounding Jack Laser Engraved for The Penman Hat Co.
10. Prototype #2 Rounding Jack
11. Prototype #1 Rounding Jack

Formillion & Conformer:

1. Formillion & Conformer, Prototypes #1 & #2

Foot Tollikers:

1. Foot Tolliker: Elk Antler & Birch Wood, on a Display Stand
2. Foot Tolliker: Walnut Wood, on a Display Stand
3. Foot Tollikers: Three in White Birch Wood
4. Foot Tollikers: Walnut Wood Set of Four
5. Foot Tollikers, Birch Wood Double Set, on Display Stand

Brim Pencil Curl & Kettle Curl Wooden Shaping Tools:

1. Wooden Hinge-Shackle Curling Tool for the Homburg Hat
2. Wooden Curling Shackles, Various Sizes
3. Wooden Groove Tolliker

Hat Block Spinners:

1. Hard Rock Maple and Walnut Ornamentally Turned Hat Block Spinners

Puller Downers:

1. Puller Downers, made in Birch & Maple

Pusher Downers:

1. Pusher Downers, made in Walnut, Hard Rock Maple, & Poplar

Stainless Steel Slip Stick:

1. “Coming Soon”, please check back.

My Website with other woodworking, including furniture, walking canes, scrimshaw artwork, custom knives, and other misc. items

Mark DeCou Studio Website

(Note:This project story, project design, photos, text, spelling, everything I can possibly list is copyrighted in 2008 by the Author, M.A.DeCou. If you want to use any part of this posting or the photos, for any Feeds, or a book, or another website, or for any reason whatsoever, even ones that I could not have dreamed about you doing before you did it, you must ask for permission first. Please)

-- Mark DeCou - Kansas Flint Hill's Artisan