How to stretch a felt hat, like a cowboy or western hat

A hat stretcher inserted into a felt cowboy hat
A vintage American Hat Co. felt western hat, with some beaver fur in there

Those of us that like to thrift, whether online or on websites like eBay, don't have a lot of choice if the hat comes in just a little small, even if the size is technically correct.

Felt hats shrink a little over time, and there can be some variance in sizing to begin with, even with non-thrifted, brand new hats. Sometimes your hat will also shrink if you leave it in a hot place, like a car.

Here's how you can stretch it back out, or a bit more than where it's currently at. It's not magic, but it can definitely help.

Watch my video on how to stretch your felt hat

Things you'll need:

Steps to stretch your felt hat

  1. Steam the inside and outside of the sweatband area of your hat
  2. Insert the hat stretcher and tighten it — do it until you hear the hat "creaking," then a little more and leave it for about an hour.

That's pretty much it, to be honest. Some time, and a little bit of effort, and your hat will fit your head much better after this process. You may need to do it a couple of times, it depends on how aggressive you get with cranking the stretcher and how much stretch you actually need.

Bear in mind, like I mention in the video, some hats have nylon or metal wires running around the inside of the sweatband. You may need to cut this out if it's present, otherwise the hat will essentially always be the same size.

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