I took a vintage block from ebay and with the belt sander, and vibrator sander, and a little elbow grease, sized it down from a 7 3/8 to his size. Plus, I transformed it into a Raiders block in the process. If anyone decides to do this on their own, be sure and get a larger block than what you want to end up with. I should have considered this method initially instead of the bondo/wood hybrid. Of course, I had no clue as to what I needed in crown shape, so using bondo(you can always add back if you err) possibly was necessary now that I think about it.
Now that I know basically what the block should look like( through trial and error), it is easier to just use a larger vintage block. And it looks so much better. The hat that the link takes you to http://public.fotki.com/Fedora/hats/mar ... ock-1.html is a cowboy hat, and the brim is 2 7/8 all the way around. The crown height is 5 1/4 bashed, on the sides, and the block is 5 3/4 open crown. I still have to cut 1/4 an inch off the bottom since Marc wants his to be 5 1/2. I like mine this tall though. regards, FedoraPS Peruse around that linked site to see the block, still unfinished, and some more views of the final product.
