Custom Cowboy Hats

Classic and Traditional Cowboy Hats

The cowboy hat
defines the wearer.

Cowboy hats aren't a fashion accessory to working cowboys, today or at any time in the prior 150 years. For a cowboy his hat is a statement of who he is, and is as necessary a piece of equipment as his rope, horse, or boots.

The Westerner

A cowboy's hat is used to feed grain to his horse, control it, or haul water. It protects his head from the weather, eyes from the sun, and prevents sun stroke. With a little care a fine beaver fur-felt hat will often outlast the owner - and in the old west of the 1870s to the early 1900s, it often did.

Lady Tristan hand made hat

1898 Roughrider hat

Nothing a traditional cowboy wore was as unique as his cowboy hat and the big hat was adjusted by working cowboys to reflect the weather conditions and terrain they faced in the different territories
of the Old West.

Everyone needs
A Good Hat

With the rise of melanoma and skin cancer - everyone needs a good hat to shield their face and neck from the harmful effects of the sun. Nothing is more timeless and useful as a fine beaver fur-felt Cowboy Hat? It will keep your face and neck in constant shade - regardless of the position of the sun, and your eyes and lips will say thankee-thankee. It'll be your friend for life and will age just as gracefully as you!

Movie Hats from
The Last Best West

For decades many of the best western movies and series have been filmed in and around Calgary, Alberta, Canada. Powerful western drama's like River of No Return, Unforgiven, Legends of the Fall, Open Range, Lonesome Dove (the series), Broken Trail, Speilberg's mini-series, Into the West, and the Brad Pitt western; The Assassination of Jesse James...., are just a few of the dozens of western's that have all been filmed up here. We know Cowboys, we know the Old West and we know Cowboy Hats.

Jake Lonergan

Grease up yer guns outlaw's
And cinch them on tight. . . .
There'll be blood a runnin',
In town before night.

There'll be gun's a blazin'
And singin' with lead
Tonight you'll be drinkin'
Your drinks with the dead.

Excerpt from
The Outlaw's Lament

The Best Cowboy Goods

City Lights Custom Hat

Custom Hat Bands.

Open Range Custom Leather Chaps.

Open Range Custom Leather Chaps.

Longfellow in the Johnny Ringo.

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The Last Best Cowboy Hat

It's the last thing you take off, and the first thing that's noticed!

Purchase one of our fine beaver/blend hats and you will receive the same quality and workmanship that is worn by more than a dozen of the world’s premier rodeo cowboy’s riding today. Production Companies, Politicians, National Security Advisors, Musicians, Writers, Cartoonists, Artists, Athletes, Soldiers, and lots of every day folk love our hats, and we hope you will as well.

All about hats and how we do it ::Testimonials :: Rodeo Champions wear our hats.

Most people know that putting a cowboy hat on a bed is bad luck - but why do cowboys feel that way? Well first off a cowboy would never wear his hat in bed and he'd only be in bed during the day if he was sick. So by putting your hat on the bed you risk bringing sickness or other bad luck on yourself.

Our custom western hats are made the old west way - one at a time, starting with the best fur-felt hat body available - made in the USA - and fashion as fine a custom western hat as you can find anywhere, for any money.

Order today and get IN time for Halloween :: You've worn the rest, now own the best!

At left is our version of the hat Gary Cooper wears in the classic cowboy movie, The Westerner. Shown in black, with optional light trail dust and available in any of our colors and made with top quality beaver blend and pure beaver fur-felt hat bodies. Continued


  • Beaver Fur Felt is dense and virtually waterproof. It consists of beaver and/or rabbit/hare fur blended with felt to produce a material that lasts 5-10 times longer than wool-felt. A fine Beaver and Beaver blend fur-felt hat can be re-blocked and shaped numerous times, and is the best material from which to manufacture hats.
  • As a general rule of thumb if a hat maker only describes their hat bodies as fur-felt, chances are it's rabbit or Hare. Hat makers who use beaver fur-felt are proud of it and will state so. We sell 3 quality beaver blends of fine western hats - 5X, 20X and 100X. 5X is a blend of about 5% beaver with rabbit and felt. Our 20X is 50% beaver and our 100X is pure 100% beaver fur-felt. The rough hat bodies we use to make our hats are the best available and made in America.

  • GENERAL PRICING includes shipping in North America
    -     5X - 350.00      5% BEAVER HAT BODY
    -   20X - 480.00    50% BEAVER HAT BODY
    - 100X - 750.00  100% BEAVER HAT BODY
    - Prices for individual hat styles will vary
  • For an all weather hat - you can't beat a pure beaver cowboy hat. Light, stiff, and fabulous looking it'll shed what ever comes it's way. And consider this: Beavers live in the water, rabbits in the dirt. CONTINUED

Crown and Brim Measurements

We make custom cowboy hats so the crown and brim measurements are pretty much redundant. The hats you see online are our standard hats, if you want a specific crown and brim height we will confirm that after your order is received. We can make up to a six (6") inch crown and a five (5") brim. Any hat with a brim width of more than 4 inches we must start with an oversized hat body, which adds a little to the cost. Most of our cowboy hats have a crown height between 5 and 6 inches and a brim width of 3 1/2 to 4 inches. Hat styles with a wider brim include The Wasey, Quigley, Everett Hitch, Blondie, Little J, The Dunson, Last of the Dogmen, Wild Bill, all our B-Movie hats, and many of our Custom Rodeo Hats.

Questions can be answered with a little exploration of our web site. Most everything about our quality custom western hats can be answered by clicking here.  For shipping times and information please click here.   ABOUT US :: SHIPPING POLICIES :: RETURN POLICIES :: CONTACT US

Order with confidence; all hat details are confirmed with Sonja within a BUSINESS
day of your order being placed.

Questions and quote requests please e-mailed to

ORDERS CALL TOLL FREE: 1-866-207-1909.  :: Overseas buyers please read this :: All Our Contact Info


In most cases, if it was made in the Past - it can be made in the Present

Most questions regarding, "Can you make. . . ."  is yes. If you've seen it in a movie, or have a picture of it - we can make it. Send us a picture of the hat you are looking for, and we will get you a quote. Like the man said, a picture is worth a thousand words, so please send a picture along with your quote requests.

Send your pricing requests to Sonja at

This is a picture of our hat liner. From the BEAVER fur-felt hat bodies to the rest of the fixings you'd be hard pressed to find a better made hat anywhere. For any price. If you don't believe us - see what our clients say on our testimonial page :: CONTACT US

We promise to make no two custom pieces exactly the same - and our originality and individuality bring clients back time and again to our order catalogue.

Our hat liner - The Last Best Cowboy Hat.

"Being a Cowboy ain't so much what yer do - it's who you are." ©
Josey Wales

Trail Dust
Many customers have been requesting that we dirty up their new hats to make them look trail worn. Pictured is a dusty Josey Wales - our Josey Wales hat with many years’ worth of trail dust - as if a hard living horse soldier had been wearing it. Inset hat shows the hat clean and unsoiled.

We've got three different degrees of trail dust. Light (add $55.00) - medium (add $75.00), and heavy (add $95.00). Light would be what you see on our BOSS SPEARMAN medium would be like the dusting on the Rossiter; and heavy trail dust looks like our Josey Wales.

This is a similar process that costume designers apply to hats in the movies and t. v. Looks authentic and yore friends will swear yer just got off a trail drive, or a hitch in the Horse Cavalry! You can add trail dust during the check out process - or request it when you call your order in.

Classic Fedoras from The Last Best West!
It may surprise a lot of people, but fedoras have been with us almost as long as cowboy hats. This style of hat debuted in 1882, in a play called Fedora, starring Sarah Bernhardt, recognized as the greatest actress of her day. We have some of the most classic styles, including this great looking one,worn by Humphrey Bogart as Fred Dobbs, in the classic adventure story, The Treasure of the Sierra Madre. Continued

Many modern cowboy hats have a Fedora or a variation of the Fedora crown. Some of these include, the Tristan, John Elder, The Professor, Dodge City, Hidalgo, Doc Holliday, and Fort Apache.

Lots of B-Westerns, Serials and Series from the 1930s and 40s would often have cowboy hats and fedoras' featured in the same scenes.

Classic Fedoras

We were excited to do some work for FOX ENTERTAINMENT early in 2014. We made a buscadero worn by Jed the Cowboy, in the upcoming Night at the Museum 3.

As well we were commissioned to make a bow quiver and a couple of arrow quivers. These were for the live action shoots, for the upcoming new version of the global gaming phenom, World of Warcraft.

In August of 2014 we were excited to have the Costume Director and Supervisor from AMC's Hell On wheels series come through our showroom! Hell On Wheels is filmed in and around beautiful Calgary AB, Canada (where we call home)!

When Carol and Michelle were done 30 minutes later they left with 10 hats, a couple pairs of chaps and assorted hat and leather accessories. Look for them in the upcoming episodes of Season 4.

Hats: Mattie Ross, Virgil Cole , Pinkerton , Tom Harte , Cimarron, 6 Shooter , Pale Preacher, Modified Hidalgo, Texas Flat Town Boss

Leather: 'A' style wrist cuffs and our Open Range chaps

Wind String - Stampede String
Heavy Latigo lace {brown or black} includes this oak, custom stained slider. You can choose either a medium or large slider, custom stained in Deadwood Brown or Old Oak. Click on the picture at right for a larger image.

Never lose your hat again with this handsome stampede string. Easily select your choices during the checkout process.

Price: $30.00 | Shipping: $12.00 | Total:$ 42.00

Order Now | Check-Out    

Custom Stampede String.
Wooden Hat Stand

Wooden Hat Stand

For years we have been looking for a good, top quality wooden hat stand. We finally got tired of trying inferior products and designed one ourselves! Hat stand is made from new, unfinished wood, glued and screwed, and comes fully assembled. Ready to be stained or painted to suit your taste. Like all hat and leather products, our hat stand and hat stretcher are made in America.

And when used with our hat retainer, perfectly holds your hat size and displays your pride and joy. Available in two sizes Tall ($45 - 17" high) and Medium ($35 - 12" high) Click pic at left for larger image.


TOTAL = $65.00/TALL :: ORDER TALL :: Check-Out

TOTAL = $55.00/MEDIUM :: ORDER MEDIUM :: Check-Out

SPECIAL OFFER Get 2 STANDS a Tall and Medium AND SAVE $15.
Two hat stands for 70.00 ADD $35.00 SHIPPING
$TOTAL 105.00 :: ORDER NOW :: Check-Out


We recommend all customers who OWN a good hat, get a hat stretcher. It Is a small cost for a tool that will help keep ALL your hats fitting properly. As well, if you only wear your hat seldom; or have a number of hats you wear, you will find our wooden hat stretcher a valuable addition to maintaining the perfect shape of your custom cowboy hat.

HAT STRETCHER FITS SIZES 6 7/8 - 8. :: PRICE: $25.00 :: Shipping: $13.00

TOTAL: $38.00 USD Order Now | Checkout

Hand Made Leather Hatbands

Freshen the look of your favorite old hat with a new hat band from The Last Best West.

Our hatbands are all made by hand, and have that authentic Cowboy flavor to help you stand out from the herd.

We still won't sell the custom hat bands that go with our great hats, but here's a selection of original hatband's to help you make your own statement. Continued

We've adapted a slider so every hat band ties off at the back and is held in place by light pressure.

It's surprising fast and you can easily take our hatband off and put it on a different hat. This design innovation gives a dang fine fit every time.

Old West Cowboy Hats

In the 19th century cowboys wanted 2 things when they bought a hat. They wanted a brim as wide, and as flat as possible and they wanted the brim to stay flat. Stetson used to market their Exclusive! Stay Flat Brim! in the mail order catalogues of the day. Traditional working cowboys knew the wider and flatter the brim, the better the all weather protection. We strive to stay true to the old time hat makers, and take care to make each clients hat just the way they want it, as if we were making it for ourselves.

True Old West Hats
Order your hat in 100X undyed, pure beaver fur-felt, and be one of the first to hearken back to an era in hat making a hundred and forty years ago. The first cowboy hats were made from 100% beaver fur-felt, natural and undyed, and unless the cowboy lost it or had it stolen - the hat lasted a lifetime. Watch the hat fade and lighten, become streaked from all weather wear, and become just as unique as the wearer. For an all weather hat - nothing beats a traditional western hat made from beaver fur - it's what old west cowboys wore.

Cowboy Hats

OUR STANDARD DELIVERY IS STILL 6- 8 weeks for our quality hand made cowboy hats.
For a complete listing of all our hats - click this link for our online catalogue.

Custom Made For. . . .
All our custom western hat's are personalized with your name, initials, or moniker stamped in gold foil on the sweat band, inside the crown. No additional charge.

1898 Bow
This was the most common bow style of the 19th century. If you prefer this bow style for any of our hats, just request it when your hat details are confirmed via e-mail.

Back in the 19th century and the first 4 decades of the 20th century, when hats were a very common part of every day dress, women's hats had the bow on the right hand side. If you want the bow on the right - request it when your hat details are confirmed via e-mail.

Click for larger image .

Order today and get IN time for Halloween!
We know Cowboys, we know the Old West and we know Cowboy Hats!
All about hats and how we do it
On our fact page you'll learn about fur felt, see available colors, and see step by step instructions for measuring your head, ordering your custom hat, shipping, and our refund policy. We also have a section on general hat care, and Cowboy Hat Etiquette. (not to be missed!)
Click here for all our Cowboy Hat Facts. The Best of the Best - order 100X . . .

A Note about Color
Color variances caused by individual computer monitors are beyond our control.
Light colors will reflect heat the best - while dark colors will retain the heat the most - with black being the worst for staying hot (black absorbs sunlight). However black is the most formal color so bowlers and top hats were generally black or dark gray. For the first 15-20 years cowboy hats were marketed - your choice of color was black and about 3 shades of brown. Please keep in mind we try to take our pictures with natural light - so differences between the same color reflects the difference in light when the picture was taken: Indoors, Outdoors, Sunny Day or Cloudy. Click here for our hat catalogue.

Questions? E-mail us at:







Click here for a large image of all the colors. Click the hat name on the picture below to link to that hat.

B-Movie Cowboy hats
In the 1920s and 30s oversized cowboy hats were all the rage made popular in the B Western-Movies of the day. These hats are big, bold, and sure to get noticed! In the 1930s the B-Western stars like William Boyd, popularized denim and showcased the modern rodeo. Click for our B-Movie Hat page.

B-Movie's were fast paced, with plenty of action and a happy ending. Just what the people needed to forget their troubles during the Great Depression. Or the Great Recession!

Testimonials :: Sassy Ladies - Our custom hat line for women.

It's not possible to show every different style of crown and brim so if you don't see what you want - send us a picture - and we'll make our version of that hat.

Questions and quote requests e-mail to
ORDERS CALL TOLL FREE: 1-866-207-1909.  :: Overseas buyers please read this :: All Our Contact Info

Everyone deserves a pure beaver western hat at least once in their life.
Then you'll know why we call it; The Last Best Cowboy Hat.

Testimonials :: Cowboy Hat Facts :: Our Hat Experts

Q: I'm looking for a ____ Hat. I checked your product catalogue and didn't see it. Can you make it?
A: Yes. As I'm sure you can appreciate it's just not possible to show all the different variations of crowns and brims. If it's made from fur-felt and you can supply us a good picture - yes we can make it. Generally we already carry the same style of hat, we just shape it based on the photo or if it's a movie hat we shape it from watching the movie and seeing the hat from all possible angles to get the look just so.

Q: Can I get the same style hatband that the original movie hat had?
A: If it's a satin ribbon and bow, or plain leather; then yes. Other than that the answer is probably no. This is likely the hardest thing in replicating a movie hat because the costume designers/actor/director/ or perhaps all three came up with a very unique type of hat band to make the hat stand out above the crowd. We make our version of the hat, and you can choose any hatband that you may see on any of the hats in our product catalogue.

Q: Do you have to put holes in the hat to put on a windstring?
A: Yes. They go right above your ears, to allow the latigo lace thru. It's the original and best way to put on a windstring. You can buy commercial stampede strings that have clips that go up under the sweat liner and jam into the crown. We hate them. They mess up the fit of the hat and they don't hold tight in a real strong wind. We know we've tried them.

Q: Can you mail me a catalogue of all your hats?
A: No we have no print catalogue - trying to be GREEN friendly. ALL OUR HATS are listed here on our online catalogue.

Q: Why does the same color appear different in your hat pictures?
A: The difference in {indoors; outdoors; bright day or cloudy day} lighting accounts for the variance in color. In addition every computer will display colors slightly different. Please understand that color variances caused by individual computer monitors is beyond our control. THE BEST REPRESENTATION OF OUR HAT COLORS IS IN THE GROUP PICTURE ABOVE.

Q: What is fur-felt/what quality do you carry?
A: Fur felt is beaver and or rabbit fur mixed with felt to produce a material that lasts 5-10 times longer than wool felt, and is the best material from which to manufacture fine hats. Click here for more information. 

Q: What's the correct way to measure my head?
A: The best is to have a helper, and click here and follow the simple steps.

Q: What colors do you carry?
A: Click for more information.

Q: Do you carry straw hats?
A: No. There's a number of reasons we don't. Straw hats were not worn by old west cowboys, they considered them peasant or farmer headware. Yes; in the deep south Plantation Owners did but that was generally before the cowboy era. Straw cowboy hats became popular starting in the 1920s with the advent of modern rodeo's. Rodeo Cowboy's didn't want to trash their good fur felt hats so they started wearing straw cowboy hats, during the events, because they were cheap. Nothings changed - they still are. We make hats that last. And the last reason is we don't find straw hats much cooler than a good, light-colored, beaver hat; and those popular Guatemalan leaf hats are such a tight weave they are really hot, and also heavy.

Most of your other questions will be answered by reading our Cowboy Hat Facts page by clicking here.

Custom Cowboy Gun Leather.

Hand Made Leather Products
All our Cowboy leather has been researched and designed; tried and tested by Longfellow in Old West Shows and at Cowboy Action Shoots. Our holsters; belts and chaps are based on pictures from museums, archival photos and mail order catalogues from the late 1800s and early decades of the 20th century.

ALL OUR HOLSTERS ARE LINED. Our gunbelt backs are suede so the belt stays where it is buckled. We try to stay as true to the old west makers as we can, and have incorporated what we found works over years of wear and use. Any of our fine leather products would suit a lady just fine. Testimonials :: Click for our Custom Leather Page

Cowboy Hat History
Contrary to popular mythology John B. Stetson did not invent the Cowboy Hat - but he certainly popularized it. Mexican and Texas Ranchers in the early to mid 1800s developed the wide brimmed fur-felt hat to offer better protection against the stifling heat and unpredictable weather of the North American West. Up until the turn of the 20th Century many mail order catalogues still referred to Cowboy Hats as "Sombreros".

The cowboy hat has since become inseparable with a certain way of life and moral conduct recognized around the world as North America's contribution to World Culture. An old cowboy once described the Cowboy Hat this way, "It's the last thing you take off, and the first thing that's noticed."

Want a great Character Cowboy Hat?
We'll give you the secret for making one - but share this with no one! Continued.

We are excited to offer a beautiful line of Artisan Hatbands hand made in America!

These great looking hatbands incorporate natural and synthetic materials in a dynamic design, to give an old hat a new look, or any hat 2 different looks!

Shown here is our Labrador hatband on our Lady hat


Hand made Artisan Hatbands

Rodeo Cowboy Hats

Traditional Western Hats

Note: Our logo is only on the
images NOT the hats.

Western Movie Hats

The Rifleman Custom Hat


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