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Hat Making Tool: Rounding Jack for Pyrate Trading Co.'s Triangular Shaped Pirate Hats

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Project by Mark A. DeCou posted 05-27-2008 07:34 PM 3127 views 0 times favorited 3 comments Add to Favorites Watch

This Rounding Jack (Brim Cutter) was a commissioned piece, and so it has been sold.

If you would like something similar, please email me at

mark@decoustudio.com

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Video: What does this thing do? Watch this video by California Custom Hat Maker Tom Gomez from Premier Panama Hats using one of my Rounding Jacks on a felt body Hat. Here is a link to Tom's ebay Store

To See More Hatmaking Tool Videos from Tom Gomez:
  1. Foot Tollikers: click here to see
  2. Kettle Curling Tool: click here to see one
  3. Puller Downer: click here to see one:
  4. Pusher Downer: click here to see one

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Customer Testimony Printed with Permission:

Hi Mark,
“I meant to email you sooner but things have been crazy around here. I love the rounding jack both aesthetically and functionally. It’s a new tool to me so it has taken a little practice; you have to be sure the hat doesn’t turn while you are sliding the jack around but that isn’t a problem. The cut is smooth and perfect. Thanks again for your great craftsmanship and for getting it made so quickly. I am sure it will be a useful tool for many years to come!”

Clay Jarratt
Pyrate Leatherworx & Pyrate Trading Co.
www.pyratetradingco.com

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Project Story:

This project is a Rounding Jack for a custom “Pirate Hat” maker in the Kansas City area so that he can cut the felt brims on the hats he makes and sells on his website and at festivals.

www.pyrate.org

The owner of Pyrate Trading Co. (PTC) found my Rounding Jacks on the lumberjock postings a few weeks ago and placed his order for one of my production models.

His Rounding Jack is serial number #2008-06
The wood used on this project is Kansas Black Walnut. The rest of the parts are yellow brass.

Display Stand: The display stand is designed to sit on the hatmaker’s work bench and hold the cutter when it is not being used. The retractable blade can remain extended this way between uses. This particular stand shown in the photos is Kansas Black Walnut. This display stand is meant to make the whole project look like a functional-art sculpture, while it serves it’s functional purpose of the Rounding Jack safely.

The Adjustable Brass Crown Band on the front of the cutter is used when the brim is to be cut wider on the sides, than on the front and back. By adjusting the curve of the brass band, the cutter is pushed away farther on the wider curve of the crown sides.

The inlay piece is synthetic ivory with Pyrate Trading Co.’s business logo scratched with a knife by hand in a scrimshaw style artwork.

To make the cut.
The blade guard knurled nut is loosened, the blade dropped down and the nut retightened. The slider nuts are loosened and the desired cut width is indicated by the pointer, and the slider nuts are tightened. The hat is placed on a wood crown block to give a firm resistance to the pressure being applied with the cutter, and the brim is placed between the bottom brass plate and the bottom of the cutter. Then, depending on whether the hatmaker is a Clockwise, or a Counterclockwise cutter, the Rounding Jack is slowly moved around the contour of the crown while pushing the cutter toward the center (head). Felt Hat Blanks are very expensive, so after the cutting is complete, a big sigh of relief is heard from the hatmaker.

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Here is a Slideshow with more of my Rounding Jacks Shown
Click the “Speaker” icon for music

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

NOTE:
ALL HAT MAKING ITEMS THAT I HAVE IN STOCK
ARE LISTED IN MY ETSY.COM ONLINE SHOP, click here to check inventory

Rounding Jacks, Collector’s Editions:
  1. Ebonized Walnut Clockwise with Laser Engraving
  2. Walnut Counter Clockwise w/Laser Engraving
  3. Walnut Uni-Directional Cutter
Rounding Jacks, Deluxe Model:
  1. Maple Deluxe Model, Counter Clockwise Cutter
  2. Maple Deluxe Model, Clockwise Cutter
  3. Walnut Deluxe, Counter Clockwise Cutter
  4. Walnut Deluxe, Clockwise Cutter
Rounding Jacks, Hobbyist-Hatter Model:
  1. Walnut Hobbyist-Hatter Model, Counter Clockwise Cutter
  2. Walnut Hobbyist-Hatter Model, Clockwise Cutter
Bench-Top Display Stands for Rounding Jacks:
  1. Walnut Bench-Top Display Stand
  2. Oak Bench-Top Display Stand
    Click here to check inventory
Customized Rounding Jacks, Personalized for Specific Hatters:
  1. Spradley Hats in Apline, TX
  2. Rachel Pollock of La Bricoleuse
  3. Brainpan Hat Shop in Sumner, WA
  4. Steve Delk's Adventurebilt Hat Co.
  5. Marc Kitter's Adventurebilt Hat Co.
  6. Pyrate Trading Co.
  7. Hatman Jack at Wichita Hat Works
  8. Inaaya Hat Co.
  9. Penman Hat Co.
Formillons & Conformateurs:
  1. Complete Restoration of a Maillard Conformateur and Formillon
  2. New DeCou Formillion & Conformer, Prototypes #1 & #2
  3. Custom Designed Conformateur Carrying & Storage Case
  4. New Plot Base Board for the Maillard Allie Formillon
  5. Maple Wrench for Tightening Formillon Thumbnuts
Foot Tollikers:
  1. Left-Handed & Right-Handed Foot Tolliker
  2. Foot Tolliker: Elk Antler & Birch Wood, on a Display Stand
  3. Foot Tolliker: Walnut Wood, on a Display Stand
  4. Foot Tollikers: Three in White Birch Wood
  5. Foot Tollikers: Walnut Wood Set of Four
  6. Foot Tollikers, Birch Wood Double Set, on Display Stand
Brim Edge Curling Tools:
  1. Hinge-Shackle Curling Tool for the Homburg Hat
  2. Full Circle Shackle Curling Tool
  3. Half Circle Shacking Curling Tool
  4. Groove Tolliker Curing Tool
Band Blocks:
  1. Thick Poplar Wood, Various Sizes and Oval Shapes, with Tapered Sides
Crown Blocks
  1. Long Oval Crown Block Sculpting Work
Hat Block Spinners:
  1. Late Turned Hat Block Spinners
Flange Stands:
  1. Heavy Duty Flange Stands
Puller Downers:
  1. Puller Downers
Pusher Downers:
  1. Pusher Downers
Hat Racks, Hat Stands, & Cedar Band Blocks:
  1. Hat Racks to keep oval shapes
Stainless Steel Slip Stick:
  1. “Coming Soon”, please check back.

(Note:This project story, project design, and photos are protected by copyright in 2008-2010 by the Author, M.A.DeCou., all rights reserved, no use allowed without expressed written permission.)

-- Mark DeCou - American Contemporary Craft Artisan - www.decoustudio.com





3 comments so far

View Lee A. Jesberger's profile

Lee A. Jesberger

6699 posts in 2728 days


#1 posted 05-28-2008 01:17 AM

Hi Mark;

Great job, it’s beautiful.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View darryl's profile

darryl

1795 posts in 3074 days


#2 posted 05-28-2008 01:24 AM

that’s some really cool scrimshaw work you’ve included in this piece!
...and as usual, you can take a simple tool and turn it into a work of art!

View Karson's profile

Karson

34915 posts in 3149 days


#3 posted 05-29-2008 04:58 PM

Great design. Another great piece of workmanship.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

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