| Project by Mark A. DeCou | posted 448 days ago | 1084 views | 0 times favorited | 5 comments | ![]() |
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This Walnut Rounding Jack has been (SOLD) and is headed to London, England.
Rounding Jack Serial Number #2008-10
Cutting Capacity: 1.25” – 8”
Cutting Path: Clockwise
Materials: Walnut, Brass, & Abalone Shell
If you are looking for a Rounding Jack, email me for more information at:
mark@decoustudio.com
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Project Story:
Rounding Jacks are used to cut the brim felt to size on fedora, western hats, cowboy hats, and several other styles. The brass adjustable curve on the front is placed against the crown, and then the cutter is moved in a rotation around the hat, keep the pressure against the crown. Setting the blade to the proper size is done by adjusting the cutter to the desired cut size, and then tightening the brass knurled knobs.


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.

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.
Laser Engraving: I am happy to offer Laser Engraving now through Flint Hills Laser Engraving with any hatmaking tool. All we need is a clear picture file of your logo, or text, or we can develop a Logo for you at an additional charge.
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 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.
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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
- Walnut Hobbyist-Hatter Model, Counter Clockwise Cutter
- Walnut Hobbyist-Hatter Model, Clockwise Cutter
- Spradley Hats in Apline, TX
- Rachel Pollock of La Bricoleuse
- Brainpan Hat Shop in Sumner, WA
- Steve Delk's Adventurebilt Hat Co.
- Marc Kitter's Adventurebilt Hat Co.
- Pyrate Trading Co.
- Hatman Jack at Wichita Hat Works
- Inaaya Hat Co.
- Penman Hat Co.
- Complete Restoration of a Maillard Conformateur and Formillon
- New DeCou Formillion & Conformer, Prototypes #1 & #2
- Custom Designed Conformateur Carrying & Storage Case
- New Plot Base Board for the Maillard Allie Formillon
- Maple Wrench for Tightening Formillon Thumbnuts
- Left-Handed & Right-Handed Foot Tolliker
- Foot Tolliker: Elk Antler & Birch Wood, on a Display Stand
- Foot Tolliker: Walnut Wood, on a Display Stand
- Foot Tollikers: Three in White Birch Wood
- Foot Tollikers: Walnut Wood Set of Four
- Foot Tollikers, Birch Wood Double Set, on Display Stand
- Hinge-Shackle Curling Tool for the Homburg Hat
- Full Circle Shackle Curling Tool
- Half Circle Shacking Curling Tool
- Groove Tolliker Curing Tool
- “Coming Soon”, please check back.
My Website with other woodworking, including furniture, walking canes, scrimshaw artwork, custom knives, and other misc. items
(Note:This project story, project design, and photos are protected by copyright in 2008-2009 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

































5 comments so far
Roger Strautman
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534 posts in 1024 days
posted 448 days ago
Where’s the hand cut text? You need to learn chip carving! I’m sure the laser work would be by far less cost than hand cut stuff. I just had to give you a hard time because there is absolutely nothing wrong with this piece. Great work again!
-- " All Things At First Appear Difficult"
Dick, & Barb Cain
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7034 posts in 1190 days
posted 448 days ago
The laser engraving looks really nice.
You must have a Laser engraver now.
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
thetimberkid
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1944 posts in 594 days
posted 448 days ago
Great job!
Thanks for the post
Callum
-- For wood working podcasts with a twist check out http://thetimberkid.com/
jeanmarc
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1750 posts in 607 days
posted 447 days ago
vey nice job
-- jeanmarc manosque france
Zee
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5 posts in 405 days
posted 395 days ago
Mark,
The goods all came in today, and I have to say I am in two minds as to use them or not. They are stunning…this Rounding Jack and stand are just gorgeous! They need to be placed in my display cabinet and not on my workbench!! It works a treat by the way!
My wife’s not letting me touch them in case I spoil them!! Oh, and thanks for the catalogues you sent – the craftmanship on your goods is humbling; it’s a rare treat to find someone like yourself who has done wonders for me! My wife’s looked at your other works and has already started thinking of what she wants to get you to do – we haven’t even found a house big enough for her plans!
Cheers for all the effort you put in, your goods really show the attention to detail you put in.
Regards,
z.