BEHIND THE CRAFT: THE MAKING OF A HERBERT JOHNSON POET HAT

At Herbert Johnson, each hat tells a story, woven from time-honoured techniques and the hands of skilled artisans. From raw materials to the finishing touches, the creation of our iconic Poet Hats is a testament to the heritage of traditional hat-making and the dedication we have to both craft and sustainability. Whether bespoke or ready-to-wear, each hat is a masterpiece, designed for those who appreciate quality craftsmanship, timeless design and traditional methods.

Step 1

The journey of crafting a Poet Hat begins with the careful selection of the finest felt. Sourced ethically, we offer a variety of options, from wool and rabbit to luxurious beaver, each chosen for its specific qualities. For a hat that will last generations, beaver felt is an ideal choice due to its exceptional durability and water repellency. However, for a more casual, occasional hat, rabbit or wool felt offers both quality and versatility. Our materials, including fur felts, are sustainably sourced, minimising environmental impact.

Step 2

With the raw felt hood in hand, we use steam to loosen and soften the material. This pliable felt is then blocked either by hand or with a metal press, depending on the design. One of our specialties is Open Crown Blocking, where the crown is shaped into a dome and then hand-molded into its final form. The Poet Hat, known for its distinct shape, truly comes to life during this phase, requiring expert skill to capture its signature look.

Step 3

Once the crown is shaped, the brim is carefully cut and refined. Using a brim block, we set the desired curve and structure, ensuring the brim complements the crown's design. It’s during this step that the character of the hat really starts to emerge, as the artisans craft a silhouette that blends both form and function.

Step 4

Every detail of the Poet Hat is a reflection of Herbert Johnson’s commitment to quality. The soft Italian leather sweatbands are selected for comfort and longevity. Each sweatband is meticulously sized, embossed with our emblem, and hand-sewn into the felt form. The final touch is often a beautifully handcrafted ribbon, shaped to hug the crown and stitched with precision.

Step 5

With the brim and crown in perfect harmony, our artisans apply the final shaping by hand. This process infuses the hat with character, as the hand-molding allows each piece to have a unique flair. Once shaped, the interior cotton lining is hand-sewn, providing a luxurious feel for the wearer.

From start to finish, the creation of Herbert Johnson's Poet Hats relies on the skills of our craftsmen, passed down through generations. With every hat, we invite our customers to become a part of our story—each Herbert Johnson hat is a symbol of timeless craftsmanship, built to be worn and cherished for years to come.