home made hat block/stretcher for my Akubra

In-depth discussion of the Fedora of Indiana Jones and all other hats appearing in the Indiana Jones movies

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enigmata_wood
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home made hat block/stretcher for my Akubra

Post by enigmata_wood »

I wanted to re-shape my Fed IV crown so the sides were dead parrallel and dome curve was flatter - for a 'boxier' look.
I also wanted a tad more snap in the brim.
I'd read somewhere on this site about a hat block made up in layers so I had a go. Credit to that person's idea.
My thought was to make a shaper that had room for the hat band and sweatband left on - so there is a 4 mm gap between the dome block and the brim shaper.
Using left over MDF, because it was cheap and easy to work, and an online calculator, I cut elipses with the precise circumference of my head - except the top elipses which were reduced to rough out the dome.
The brim shaper is larger all round than the hat brim - to give me the later option to use it for other hat projects.
A whole lot of gluing, whittling and sanding later - and three legs from an old 50's sideboard - and I have what looks like something from a 50's Sci-Fi movie. Perhaps Great Uncle George was really aiming for this look when he thought up the end to Crystal Scull?
The MDF is weighty enough to stretch the dome nicely and I found my Todd's belt ideal for tensioning a tea-towel across the brim to hold it till dry.
If you are going to make your own block I have two words of advice:
measure and draw very carefully, redrawing your guide-lines whenever they start to rub away,
work on a clean bench and keep back the sawdust - you can mix it with wood glue to make a matching filler for any over zealous wittling.
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fenris
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Re: home made hat block/stretcher for my Akubra

Post by fenris »

I had the very same idea to use MDF before, but I thought it might be difficult to use as a block due to it turning to powder when soaked in water.

Did you seal the MDF with putty or primer (can't remember what it is specifically called, sorry)?
enigmata_wood
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Re: home made hat block/stretcher for my Akubra

Post by enigmata_wood »

fenris wrote:I had the very same idea to use MDF before, but I thought it might be difficult to use as a block due to it turning to powder when soaked in water.

Did you seal the MDF with putty or primer (can't remember what it is specifically called, sorry)?
No, but then when I tried it, it was only with a damp hat. If i see any sign of 'powdering' I will probably seal it with PVA or even waterproof wood glue.

BTW, the hat came out great. [yes, I will post a picture at some point]
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fenris
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Re: home made hat block/stretcher for my Akubra

Post by fenris »

It usually takes time before the MDF eventually turns powdery... but it can swell up due to moisture. Had that happen to one of my subwoofer boxes in the car. Apparently the trunk lid had a small gap which allowed some rain to seep in causing on side of the MDF-made box to swell.
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Indiana Greg
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Re: home made hat block/stretcher for my Akubra

Post by Indiana Greg »

BRILLIANT! I want to buy one! Any chance you might make some for sale?
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fenris
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Re: home made hat block/stretcher for my Akubra

Post by fenris »

Oh, maybe you could post another pic of it... this time with it not inside the hat. :TOH:
enigmata_wood
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Re: home made hat block/stretcher for my Akubra

Post by enigmata_wood »

Indiana Greg wrote:BRILLIANT! I want to buy one! Any chance you might make some for sale?
I don't think I could make them profitably and charge a reasonable price. This one was at least a day's work in total hours.
enigmata_wood
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Re: home made hat block/stretcher for my Akubra

Post by enigmata_wood »

fenris wrote:Oh, maybe you could post another pic of it... this time with it not inside the hat. :TOH:
I'll try to do so tomorrow.
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Re: home made hat block/stretcher for my Akubra

Post by enigmata_wood »

As requested here's the picture of the block without the hat.
The dark bands are filler made from the sawdust mixed with wood glue.
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Fedora
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Re: home made hat block/stretcher for my Akubra

Post by Fedora »

Great job. Hey, would you post a pic of the hat, after you reblocked it? I would love to see how it turned out. Fedora
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Re: home made hat block/stretcher for my Akubra

Post by Local Land Surveyor »

Awesome!! :tup: .
Nice touch with using the Indy belt as a tie-down. Of course, if you reblock a TOD or Crusade hat on it, you would need to use the tan belt. ;) :TOH:
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Re: home made hat block/stretcher for my Akubra

Post by Renderking Fisk »

Has anyone ever noticed that hat blocks are actually ROUND.

I made one with plaster once, $25 down the drain when it crumbled when I tried to use it the first time.

What would be the best wood to use to make your own? I have a bunch of pine and oak in my basement.
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Re: home made hat block/stretcher for my Akubra

Post by WalkingEye »

Eric, if you're gonna use pine or other very softwood make sure it doesn't have copius amounts of pitch! Also, be prepared for the wood checking from the heat and moistured used in blocking. The oak will potentially last longer but it will take far more effort to actually cut and carve the block. Poplar makes for good hat blocks.
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Re: home made hat block/stretcher for my Akubra

Post by Renderking Fisk »

Next question - where can I find poplar? Home Depot?
enigmata_wood
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Re: home made hat block/stretcher for my Akubra

Post by enigmata_wood »

Fedora wrote:Great job. Hey, would you post a pic of the hat, after you reblocked it? I would love to see how it turned out. Fedora
I finally got round to my full gear shots last week so, yes, soon you will see
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