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Custom Sizing
the Hat for the Customer
All Knot-Head Hats are fine artistic sculptures, but in addition,
they may be worn. The first question generally asked is, “Aren't
they heavy?” These works of art are the approximate weight
of a felt hat (7-11 ounces) and are durable. They are impervious
to rain, but like any fine work of art, should be treated with
respect. Using a curvex flexible ruler, Chris measures the head
to determine not only size but also exact shape. Unlike felt hats,
wooden hats, if they are to be comfortably worn, must be carefully
configured individually for each customer. |
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Selecting
the Wood
Because most hats are fashioned from native Kentucky woods, Chris
spends a great deal of his time appraising downed or felled trees
to find the perfect piece. The beauty of the grain, the inclusion
of bark, the imperfections of fungal invasion (spalting), the
work of the Ambrosia beetle, and the burling of the wood all contribute
to the magnificence of the art. Within each ‘blank’
is a hat waiting to be released. |
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Preparing
the Blank
Using a Stihl Model 066 chain saw with a 36-inch bar, Chris not
only cuts the approximate size of the hat, he also makes the blank
as round as possible prior to placing it on the lathe. Because
balancing of the wood is of primary importance proper preparation
of the blank reduces turning time as well as wear and tear on
the lathe and tools. |
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Rounding
the Blank
The blank is placed on the lathe and carefully centered for weight.
With the turning speed set at a moderate pace, the initial process
of outer shaping begins. Shavings vigorously fly through the air
and moisture being released from the wet wood is released. Care
must be taken at this point to obtain a perfectly rounded blank
with no torn grain, splits or checks. |
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Initial
Shaping of the Hat
The type of hat to be turned determines the outer shape of the
blank. If the rim is to be a rolled-edge (such as in a derby hat
or bowler) then this must be turned as the outer shape is defined
by the artist. |
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Hollowing
the Hat
With the basic outer shape obtained, the hollowing process is
begun. Beginning at the outside of the brim and working toward
the center of the hat slow, careful removal of the wood is accomplished.
During this process, Chris constantly measures the hat’s
thickness with a final goal of 3/32 of an inch. Great care must
be taken at this point due to the living nature of the wood which
tends to move, depending upon the character of the grain, the
direction of the cut, the type of wood selected and the amount
of moisture contained in the wet wood as the piece dries. |
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Optional
Carving
Some collectors wish to have the logo of their favorite sports
team carved into the front of the hat (especially with the baseball
cap.) This process is done entirely by hand and is labor intensive.
The logo is available in both dyed and natural wood. |
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Final
Removal of Wood
Because of the shape the thickness of the entire hat cannot solely
be determined by mechanical means, the artistic eye of the hat’s
creator must ascertain by feel, sound of the tools as they cut
the wood, and by sight, the appropriate thickness of the hat.
By placing a low-wattage bulb inside the crown of the hat and
working in near-darkness, the turner uses light, sound and traditional
measuring devices to guide him as he removes as much of the waste
as is ‘right’ for that individual piece of wood. The
light generated by the bulb causes the hat crown initially to
appear a glowing red color. This gradually become brighter as
the hat approaches the correct thickness. |
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Sanding
Sanding is begun while the hat is still on the lathe. This allows
the hat to rotate and the sanding to be even. Chris begins with
a coarseness of #120 grit sandpaper and continues the mechanical
sanding until a grit of #320 smoothes the hat to a fine natural
finish. |
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Burnishing
the Hat-Band
The hat-band is approximately 1/32-inch thicker than the crown.
This gives the appearance of an ‘attached’ hat-band.
A contrasting colored piece of wood is used to apply the hat-band
color (generally Chris uses Ebony, Padauk, Purple Heart or Rosewood,
depending upon the color desired.) The complementing wood is burnished
on the raised hat-band and the color is miraculously absorbed
by the hat. |
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Bending
and Final Shaping
Immediately after the hat has been turned and sanded it is placed
in a custom-made jig so that the bending and final shaping may
begin. The brim is stressed and gentle side pressure moves the
hat from round (as it came off the lathe) to oval (the shape of
the customer's head.) Heat lamps are applied to dry the wood in
an even manner. Rubber bands are used to assist in the bending
and shaping. |
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Final Hand
Sanding
After approximately 3-5 days of bending, shaping, drying, and
constant around-the-clock attention from the artist, the hat is
hand-sanded removing all imperfections and tool marks. This tedious
but necessary work achieves a magnificent finish for the work
of art. |
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Applying
the Finish
Approximately twenty coats of lacquer are applied in a controlled
environment, over a period of several days, depending upon the
type of wood. Each coat brings out the natural beauty of the wood.
The final coats are ‘misted’ on the hat to give a truly
radiant final appearance. |
