CUSTOM, HANDMADE
HATS SINCE 1912
Crafted in the Black Hills of South Dakota.
Photo Credit: ME PIX Images
Built for You
A great hat isn’t defined by a size tag.
It’s defined by balance, comfort, and how it settles into the person wearing it.
At Weather Hat Co., every custom hat begins with the shape of the individual — not a chart, not a template, and never a shortcut. The result is a hat that wears easier, lasts longer, and feels right from the first day forward.
Learn More About Weather Hat Co.From Measurement to Final Fit
Every custom hat follows a deliberate path.
We begin by mapping the exact shape of your head — not to determine size, but to understand form. From there, a custom head block is created and used throughout the hat-making process. The hat is shaped, refined, and finished by hand, with the final brim shaping done in person to suit the wearer’s face.
No two hats follow the exact same path — because no two heads do.
Recent Work from the Shop
Brick
Open Crown
Cattlemans
Open Crown
Arena
Custom Design
Hat Services & Restoration
A good hat is meant to be worn — and cared for.
We offer professional cleaning, reshaping, sweatband repair, and restoration services for quality hats of all kinds. Whether it’s a daily wearer or a hat with history behind it, our approach is the same: respect the material, honor the style, and never rush the work.
From the Shop
Recent work, shop updates, and a closer look at how hats are made here.
Is a Cap a Hat?
Short answer? No. A cap is a baseball cap. It has a bill, a soft crown, and it was built for utility—shade your eyes, keep…
The Grizzly Is Back
Every so often, a style comes back around that never really left. The Grizzly is an unsanded felt — intentionally left with a natural, fuzzy…
Hat Care: Small Habits That Make a Big Difference
Most hats aren’t ruined in one big moment. It’s the little things — dust left to settle, moisture that never quite dries, sweatbands that don’t…
Start With a Conversation
Custom hats are personal.
They’re best built through conversation.
You’re always welcome to call, visit, or stop by the shop. The Custom Hat Inquiry form is simply a way to share what you’re drawn to before we connect — nothing is locked in, and final details are always discussed in person.