Design Your Custom Hat

Every Greeley Hat Works hat is handcrafted right here in Greeley, Colorado, by people who love the process and are proud of what they make. When you commission a custom build, you are not just ordering a hat. You are creating a piece of wearable art that starts with your story and ends with something unrepeatable.

Current production timeline: approximately 3–4 months.

Our team will contact you after purchase to discuss every detail of your build.

Felt Quality

Your hat begins with the material. Every build starts with your choice of quality and color. The material determines everything that comes after it: the weight, the durability, the water resistance, the way the hat ages over years of wear.

Chart from Greeley Hat Works showcasing the various custom cowboy hat crown shapes, head shapes and sizes

Crown Shape

The crown is the personality of the hat. Choosing the perfect hat shape can be daunting, but at Greeley Hat Works, we have a style for everyone. While the classic Cattleman remains our most popular style, we have many other shapes to suit any taste.

We build our hats to standard crown height based on head circumference. If you have a specific preference, note it when our team contacts you.

Whether you're looking for a traditional Western crease, a classic fedora, or a style with some extra #HATitude®, you'll find a shape that looks great on you.

Chart from Greeley Hat Works showing the various brim shapes available for custom cowboy hats

Brim Shape

The brim is the silhouette — the thing people see from across a room.

The first two styles are our most popular amongst our western customers. The rest of the shapes depend on the look you’re going for, which you can see in the image.

GHW Standard brim width: 4¼ inches. Specify your preference when our team reaches out.

We have some daytime/fedora variations as well as variations that add a little #HATitude® to a “cowboy hat.”

Trim Options

The hat band finishes the hat and is often the first place personality shows. GHW builds self bands with buckles to seamlessly match your hat or ribbon trim and bow finishes.

Additional hat band options are available separately in our accessories collection.

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Self Band With Buckle

A true expression of our sustainability mission, the self band is born directly from your hat. Our hatters take the material from the precision trim of your raw brim. That initial piece of premium felt is then meticulously shaped to ensure a flawless color match and a seamless design.

To secure your self band, we offer several distinct buckle options to anchor your custom build.

Our sterling silver SK Buckle comes included on Pure Beaver quality hats. They are available on other qualities for an additional charge.

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Ribbon Band and Bow

We offer a wide selection of ribbon bands with various options for bows and keepers.

Hat Liner

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Satin Liner

Your liner is your secret. Nobody sees it but you and whoever you hand your hat to.

Choose from our current selection of solid colors and woven brocade patterns, all hand-finished in the shop.

Sweatband

The sweatband is the finishing touch inside the hat and the detail that makes it unmistakably yours. It is the only part of the hat that is in constant contact with your skin, serving as the foundation for a perfect, custom fit. A premium sweatband doesn't just provide comfort, it molds to the unique architecture of your head over time.

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Premium Sweatband Material

We source a wide variety of high-quality leather options, choosing hides that are supple, durable, and naturally moisture-wicking.
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Custom Sweatband Printing

To truly cement your legacy, we offer custom interior printing. Using traditional hot-foil stamping techniques, we can press your name, a significant date, or quote directly into the leather. Choose from a selection of premium foil colors to match the style of your build.

The Fit: Your Head Shape

A custom hat built to the wrong shape is just an expensive hat. GHW builds to your exact head shape which is why the fitting matters as much as the design.

If We Have Your Pattern On File

If you have visited GHW or one of our trunk show locations, your head pattern may already be on file in our catalog. We will look it up and build your hat to your exact shape, no second fitting required.

This is one of the reasons we keep every pattern. Your hat is already halfway built before you place the order.

If We Don't Have Your Pattern

We will need your measurements. The best option is a professional fitting at our Greeley shop or one of our exclusive retail partner locations. If that is not possible, you can take your own measurements at home.

How to Measure at Home

Step 1 — Watch the guide: Trent walks you through the full process.

Step 2 — Gather your tools: flexible measuring tape or string, two rulers, and a camera.

Step 3 — Take two measurements:

  • Head Circumference — measure around the widest part of your head, just above your eyebrows, where you want the hat to sit.
  • Crown Depth — measure from the center of your forehead to the crown of your head using two rulers as reference points.

Step 4 — Take five photos: Front · Top · Side · Close-up on the tape measure · 90-degree angle from the top of your ear.

Our team uses these to visualize your head shape before the build begins.

Step 5 — Email your photos to retail@greeleyhatworks.com, be sure to include your order number.

What Happens After You Order

You will hear from our team. Every custom build starts with a conversation, where we take your ideas and our optios into what we call the design funnel.

Our team will contact you to confirm your specifications, discuss your style, shapes, and make sure every detail is right before we start production.

The hat does not get built until we know it is exactly what you want.

Production timeline: approximately 3–4 months from confirmed specifications.

If this is your first GHW hat, you are in good company. We have built hats for Presidents, celebrities, ranchers, feedlot workers, and everyone in between. Every hat gets the same care, the same materials, and the same standard.

There is a feedlot worker's hat hanging in our shop. He wore it every single day for over thirteen years. Did the math himself 4,748 days. $0.39 a day. That hat is still on our wall because he said it better than we ever could.

Ready to Start Your Build?

Order Your Custom HatBook a Fitting Appointment