My Akubra Federation reblock project [UPDATED]

Scandinavia Jones · Post by **Scandinavia Jones** » Tue Oct 26, 2004 2:05 pm

For some time ago, I started planning how to reshape my badly tapered Fed. My GF's dad is quite the craftsman, and when I asked if he could manage to make a hat block, he gave it a shot.

Guided by Marc's block diagram and valuable info, graciously provided by Fedora, I made a rough estimate on the block's general dimensions. A first prototype was made, and I thought I'd sacrifice my Akubra Federation on the altar of science... after all, a great hat like the Akubra would not take any serious damage... right? 8-[ Besides, I figured the hat couldn't get any worse, really... it looked like this:

Anyway, I made the lid a nice, hot bath of water and mild detergent, and down it went:

The mop handle was a necessary tool... the poor thing didn't want to stay below otherwise.

After a couple of hours soaking, I yanked the hat onto the block. It made kind of a hissing sound when water pressed through it's pores or something... then, I let the blocked hat rest for a while.

Something looked very wrong, though... the top was too flat, and the hat was horribly elongated. It wasn't right at all...

Oh well... back to the drawing board... A rounder dome was to be shaped and the block needed to be seriously shortened. After a couple of weeks, it was time for round 2. When I got the block back from the GF's dad, I scrutinized it... still too long, and the dome was still too flat... either way, I reblocked the hat to see what was to be changed.

Looking better, but not quite good enough...

A quick bash... while the block was still too long, thus distorting the profile of the hat, the front view showed a far better Raiders bash than I ever achieved with the original Akubra block.

Still, a lot more tweaking was needed. An even more rounded dome and another half an inch taken off the sides... making progress, undoubtedly.

Here we go... the block in it's final shape. But how would the hat respond?

And there it is, ladies and gentlemen... my final reblock. Open crowned, it looks kind of... OK, I guess...

The metal wire showing under the brim is removed from the sweat band.

Side view. Kind of good shape... Haven't done anything to the brim though.

This is what my Fed looked like out of the box.

Front view. Hat looks a bit lopsided due to the soft transition between crown and brim.

I have yet to bash the hat and re-attach sweat & liner. Once I'm done, I'll add the pics here...

ob1al · Post by **ob1al** » Tue Oct 26, 2004 2:19 pm

Dang! Just wish I was a size 60, I would have my HJ over to you like a shot!

Impressive work my friend - most impressive.

Can I ask why "hot bath of water and mild detergent"? Is the detergent (I take it that means washing powder) to be advised on felt? Never heard of that before if so, but then I don't know too much about reblocking a hat either.

The block looks great now in my opinion.

Once you're done shaping the lid, be sure to post another pic mate.

Well done!

Scandinavia Jones · Post by **Scandinavia Jones** » Tue Oct 26, 2004 2:29 pm

Thank you, my man!
Basically, I wanted to clean the hat while I had it disassembled - hence the washing powder. I used a special kind intended for delicate fabrics - worked very well.

More to come...

Fedora jr. · Post by **Fedora jr.** » Tue Oct 26, 2004 4:25 pm

Great work man. As Al said, pics would be awesome.

Geoff

Swindiana · Post by **Swindiana** » Tue Oct 26, 2004 8:00 pm

Excellent!

It looks like you made an every bit as good a success as I would have expected with it. Never doubted ya, buddy.

Don't be surprised if you find a hat with a bit of London smog distressing on it on your doorstep for a reblock.

Regards,
Swindiana

Indiana Jerry · Post by **Indiana Jerry** » Wed Oct 27, 2004 2:34 am

SJ - can't wait to see how it looks after you rebash it! don't forget to show us, please? - J

Scandinavia Jones · Post by **Scandinavia Jones** » Wed Oct 27, 2004 3:10 am

Thank you for the kind words, guys! Pics have been delayed, though... I came to the conclusion that I'd probably be able to work a bit more of the brim into the crown, thus making it a wee bit taller... Fed's back on the block... I'll let you know...

3thoubucks · Post by **3thoubucks** » Thu Oct 28, 2004 3:24 am

I'm making a block at this time myself. I don't know which of the movie hats you're going for, but this is a pic of a block of Fedora's that he once posted, that comes closest to his home-made Raiders block. It's what I'm trying to make. (Thanks Fedora!) http://www.raidershat.com/block.jpg

Scandinavia Jones · Post by **Scandinavia Jones** » Thu Oct 28, 2004 10:33 am

Got the hat off the block this afternoon. Results are very nice!
Now, I'm in the process of sewing back the sweat (oh... joy)

Pics to come when I get home from work.

VP · Post by VP » Thu Oct 28, 2004 12:17 pm

Not bad. I could make a block too.

Renderking Fisk · Post by **Renderking Fisk** » Thu Oct 28, 2004 12:23 pm

I made a plaster block that didn't come out this good and the shape was lacking. How much work did your wooden one take?

Those results are awesome.

Scandinavia Jones · Post by **Scandinavia Jones** » Thu Oct 28, 2004 6:40 pm

Here we go:

A temporary bash and no ribbon, just to show you where it's going...

Kinda more 'squarish' look to the lid...

... and here's a side view, with ribbon & bow... I especially like the inverted taper in the back.

I never cared for the way the Akubra sweat showed under the brim, so I cut away the base part and sewed the main sweat on, like this...

This, IMO, makes the Fed less a 'bush hat' and more a dressy fedora.

I'm also quite happy with the way I managed to shrink the hat a whole size. Being a cautious fellow, I ordered a 61, which turned out to be too big. Now, the lid is a smallish 60.

Some finishing touches, finishing the ribbon and liner and then I'll post some 'wear' pics... I gave the hat a slight turn which is emphasized by a tight ribbon and the general tighter fit... looks awesome to me...

@Ren - it takes several work hours with a belt sander to achieve the basic shape. Then, it's all a matter of (careful) tweaking... hence my 4 different test reblocks. Every time, the shape got closer and better...

More to come. Thanks again for your kind words.

Mola Ram · Post by **Mola Ram** » Thu Oct 28, 2004 7:11 pm

YOU REMOVED THE REED!!

That hat will be alot less stable now, and you will need
a new sweat if you send it to someone to get it reblocked.
That would be a pain in the arse to put back in.
Adam

Swindiana · Post by **Swindiana** » Thu Oct 28, 2004 7:13 pm

Oh, I like those contours man!

Start wearing, shoot some pics, don't wanna lose that "hat hair-do"...

And the globe is a, what, size 123?

Regards,
Swindiana

Scandinavia Jones · Post by **Scandinavia Jones** » Thu Oct 28, 2004 7:25 pm

Molorom wrote:YOU REMOVED THE REED!!
That hat will be alot less stable now, and you will need
a new sweat if you send it to someone to get it reblocked.
That would be a pain in the arse to put back in.
Adam

The reed? Good riddance. I'd rather have an 'unstable' hat, than having the sweat showing. A sweat should be inside the hat, IMO.

Renderking Fisk · Post by **Renderking Fisk** » Thu Oct 28, 2004 10:32 pm

I would like to know more about your test blocks.... good going, Scandinavia.

3thoubucks · Post by **3thoubucks** » Thu Oct 28, 2004 11:09 pm

The hat looks surprisingly Raiders like, even though I'm thinking less dome, and a squared transition is the way to go, that hat has a lot of dome unbashed. I mean, did the Raiders hat have, say, a 5 5/8 inch open crown with a sharp transition or a 6 inch crown with a rounded transition? I'm confused. ....Do you have a pic from the back so the top bash is visible?

Scandinavia Jones · Post by **Scandinavia Jones** » Fri Oct 29, 2004 6:27 pm

3thoubucks, I'll post a center dent pic later - batteries in my digicam are dead... no wonder - they served during the UK summit...

Before digicam ran out of juice, I managed to get some pics of the (almost) finished creation. I'll still need to sort out the back of the brim (no flange available, so I'll have to work the back curl a bit).

As you can see, the back of the brim is a bit dodgy. I'm quite pleased with brim front and crown, though.

3thoubucks wrote: I mean, did the Raiders hat have, say, a 5 5/8 inch open crown with a sharp transition or a 6 inch crown with a rounded transition?

IMO, in order to get a good enough center dent, the crown must be quite rounded. One of the mistakes I made when designing the block was a much too flat crown... no dice. The final block can take a 6" crown - however, I couldn't work my Fed up to that height - not without losing the brim alltogether.

Ren - I'll get you more info on the block.

Neolithic · Post by **Neolithic** » Fri Oct 29, 2004 7:08 pm

This looks beautiful, Scandy. I've not seen anyone post pics of an Akubra that looks this cool. Hope you get it exactly as you want it, either way- it's looking like how I'd want my HJ!

Scandinavia Jones · Post by **Scandinavia Jones** » Sat Oct 30, 2004 6:23 am

Neolithic wrote:I've not seen anyone post pics of an Akubra that looks this cool.

Thanks, Neo - I appreciate it!

Canyon · Post by **Canyon** » Sat Oct 30, 2004 6:30 am

Looking good my friend.

You're certainly braver than I am.

Swindiana · Post by **Swindiana** » Sat Oct 30, 2004 8:31 am

-Wasn't there a boyband around called the same thing?

-Fed's on the new block!

Sorry. 'Tis a silly joke.

Looking good buddy. Love the back of the crown in that pic.

Regards,
Swindy