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A finished silverbelly felt hat with a Gus crease on a worn wooden workbench, with shelves of hat blocks and an iron crown press in the workshop behind it

By hand.One at a time.

Custom felt hats built to your head in our shop on Main Street in Bryan, Texas. Same family, same machines, since 1983.

Build your hat Help me choose

Made to orderShips in about 8 weeks

Four felt qualities, from $389

How a hat is made

Every hat we make starts the same way. Here is yours.

  1. Step one of five. The body

    It starts as a soft cone of fur felt.

    No crown, no brim, no shape yet. The fur decides how the hat wears: how it sheds rain, how long it holds a crease, how it feels at hour ten in the saddle. We build four grades and we price every one of them plainly.

    • 10X$389100% rabbit. A good first real hat.
    • 20X$549Rabbit and beaver blend. Everyday and dress wear.
    • 50X$749Higher beaver blend. Silk lining, premium sweatband.
    • 100X$999100% beaver. Lambskin sweatband. The best we make.

  2. Step two of five. The block

    Then it's blocked to your head.

    Steam, a wooden block in your size, and hands that have done this for forty years. We shape to your head oval too: round, wide, regular or long. Don't know yours? Order anyway. We'll call to confirm before we block a thing.

    How to measure your head in one minute

  3. Step three of five. The crease

    Creased by hand, the way we did the first Gus.

    In 1989 we became the first hatter to advertise and sell the Gus crease from Lonesome Dove. Today we shape twenty-one styles, Gus to Cattleman to Open Road, and every one is set with steam and thumbs. Brims from 3 to 5 inches. Crowns from 5¼ to 6.

    See the 21 styles

  4. Step four of five. The trim

    Finished in your color and your band.

    Eleven felt colors, black through natural. A two-cord ribbon band comes standard; horsehair, custom ribbon or a self band with a buckle are a few dollars more. Silk lining and a leather sweatband go in last.

    • Black
    • Chocolate
    • Darkbelly
    • Saddle tan
    • Dark grey
    • Steel grey
    • Medium grey
    • Silvermist
    • Silverbelly
    • Bone
    • Natural

  5. Step five of five. Yours

    Then it's yours, for a long time.

    We call within two business days of your order to confirm every spec, then give you a ship date. Hats leave Bryan for nearly every continent. And when the crown finally softens years from now, send it back. We rebuild the hats we make.

    Build your hat Come in for a fitting

Start where you are

Most people who walk in don't know their head size or what 20X means. That's our job, not yours. Pick the door that sounds like you.

  • I know my style

    Pick one of 21 creases, choose your felt and color, and build it online in about five minutes.

    Shop custom felt hats

  • Help me choose

    Five questions about where you'll wear it and how often. We suggest a style, a grade and a color.

    Find your fit

  • It's a gift

    Choose the style and grade now. Whoever wears it confirms size, brim and crown with us by phone later.

    Gift a hat

  • Bring an old hat back

    Restoration is $255 with return shipping and takes four to six months. Send photos first and we'll tell you what we can do.

    Start a restoration

  • I just need a straw for summer

    American Hat Company, Resistol, Rodeo King and more, shaped in house to your photo before they ship.

    Shop straw hats

Twenty-one styles

See every crease

What most people leave with

Forty-three years on Main Street

Only place my husband will take or buy his hats. Two and a half hour drive each time, one way.

Google review, one of 233 at 4.5 stars

Family owned since
October 1983
Hats made each year
About 4,000
First hatter to sell the Gus
1989
Shipped to
Nearly every continent
Google
4.5 stars, 233 reviews
Facebook
92% recommend, 513 reviews
Worn by
Willie Nelson, Charlie Daniels, Aaron Watson
Two brown felt hats side by side on a workbench: a sweat-stained, sagging old hat next to the same hat cleaned, reblocked and rebanded

Make your priceless hat like new again

Sweat, sun and years take the shape out of a good hat. We clean it, reblock it, recrease it and reband it, and we tell you in writing what we will and won't replace before we start. $220 for the work plus $35 return shipping. Four to six months in the shop, longer in fall and winter.

Start a restoration
Inside the Catalena Hatters shop, shelves lined with felt and straw hats

Come see us in Bryan

203 N. Main Street, historic downtown Bryan, ten minutes from Kyle Field. Walk in for a fitting, a shaping or a look around the shop. Texas Rose Boutique is next door at 205.

Monday to Friday
9am to 6pm
Saturday
9am to 3pm
Sunday
Closed
Get directions Call 833-430-HATS