About WhipperWill Hats

Custom felt hats, shaped by hand in Canada.

A fishing net and fishing rod lying on a wooden dock with a wide-brimmed hat resting on the edge. In the background, a peaceful lake with trees and a cloudy sky reflected on the water.
A fishing net and fishing rod lying on a wooden dock with a wide-brimmed hat resting on the edge. In the background, a peaceful lake with trees and a cloudy sky reflected on the water.

WhipperWill Hats started from a simple interest in making better hats by hand. What began as a personal project slowly turned into something more serious, one shaped crown, one rebuilt brim, and one tool at a time.

The work is still small on purpose. Every hat is shaped by hand, with attention to fit, proportion, felt quality, and how the finished hat is actually going to be worn.

A man wearing a black cowboy hat with orange braided band, sunglasses, and a high-visibility safety jacket with yellow and orange reflective stripes stands outdoors in a snowy, overcast environment. displaying the rugged durability of a good hat
A man wearing a black cowboy hat with orange braided band, sunglasses, and a high-visibility safety jacket with yellow and orange reflective stripes stands outdoors in a snowy, overcast environment. displaying the rugged durability of a good hat

How We Work

A good hat is not just about picking a colour and crown shape.

Fit matters. Head shape matters. Brim width, crown height, felt stiffness, band choice, and finishing details all change how a hat feels and looks. The goal is to work through those choices carefully before the hat is shaped, so the finished piece makes sense for the person wearing it.

What We Make

Custom felt hats
Western, outdoor, and fedora-style hats made to order.

Cleaning and reshaping
Careful work for felt hats that need to be cleaned, steamed, reshaped, or brought back into better condition.

Hat-making tools
Blocks, fitting tools, and digital files made for hatters and makers building their own setup.

The tools came from our own shop needs first.

Hat-making equipment can be expensive, hard to find, and difficult to collect when you are just starting out. Making our own blocks and tools became part of the process, and eventually became a way to help other hatters build their own setup one piece at a time.

a hat makers bench with various tools including haat blocks, felt cloths, brim curlers and a steamer
a hat makers bench with various tools including haat blocks, felt cloths, brim curlers and a steamer

Have a question or want to start a hat?

Whether you are looking for a custom hat, need an old one cleaned and reshaped, or want to ask about hat-making tools, send a message and we can figure out the right place to start.