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.

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 can build 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 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.

Sterling Silver buckles are available for an additional charge.

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Ribbon Band and Bow/Keeper

We offer a wide selection of premium ribbon bands with various options for bows and keepers. Because we utilize varying widths, textures, and structural combinations, the possibilities are virtually limitless. 

Whether you prefer a minimalist band or a formal dress bow, every piece is measured, cut, and tacked to the crown by hand.
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Ribbon Colors

Select from our deep spectrum of ribbon shades to dial in the exact look of your band. Whether you want a tone-on-tone that blends seamlessly into the felt or a bold contrast to define the crown, our Italian ribbon is selected specifically for long-term durability and beauty under any conditions.

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.

A liner isn't just decorative, it is a functional shield between your hair and the raw fur felt.  It protects the interior crown from natural hair oils, sweat, and friction.

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 Sweatbands

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

Unlike synthetic inserts, our premium leathers breathe and mold directly to the unique architecture of your head over time, breaking in like a fine pair of boots. 
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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.

Our hat experts will help you determine the character limits, punctuation, and layout for your custom foil stamping.  

We offer hand-burned marks for an additional fee. Instead of hot-foil printing, your custom design or logo is branded directly into the leather using a heated iron, creating a rugged, permanent mark that wears in with the hat.

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 it proves the value of quality better than we ever could.

Ready to Start Your Build?

Order Your Custom HatBook a Fitting Appointment

Hat Shapes Gallery

Explore our signature showroom custom hat shapes from four distinct angles to see how each crown crease and brim profile looks in real life.

Fort Worth + Soft Cattleman — 45 degree viewFort Worth + Soft Cattleman — straight on viewFort Worth + Soft Cattleman — side viewFort Worth + Soft Cattleman — top view

Fort Worth + Soft Cattleman

Crown: Fort Worth
Brim: 4 ¼" (Front: 8, Sides: 3½)

A soft, approachable take on a traditional Western silhouette. Features a gentler crown crease paired with a gradual soft cattleman brim roll for an easygoing, broken-in feel.

Defined Cattleman + Cattleman  — 45 degree viewDefined Cattleman + Cattleman  — straight on viewDefined Cattleman + Cattleman  — side viewDefined Cattleman + Cattleman  — top view

Defined Cattleman + Cattleman 

Crown: Defined Cattleman
Brim: 4 ¼" (Front: 6, Sides: 3 ¼")

One of the most popular Western shapes. Features crisp, defined crown creases and classic side dents, perfectly balanced by a standard 4 ¼" Cattleman brim.

Shallow Cattleman + Quarter Horse  — 45 degree viewShallow Cattleman + Quarter Horse  — straight on viewShallow Cattleman + Quarter Horse  — side viewShallow Cattleman + Quarter Horse  — top view

Shallow Cattleman + Quarter Horse 

Crown: Shallow Cattleman
Brim: 4 ½" (Front: 6 ½, Sides: 3 ½")

A slightly less-deep Cattleman crown paired with a wider 4 ½" Quarter Horse brim. Offers extra sun protection and a clean, balanced look.

Cutter + Cattleman  — 45 degree viewCutter + Cattleman  — straight on viewCutter + Cattleman  — side viewCutter + Cattleman  — top view

Cutter + Cattleman 

Crown: Cutter
Brim: 4 ⅜" (Front: 7, Sides: 4 ¼")

Features sharp front pinches on the crown with a wider 4 ⅜" brim to keep the sun out of your eyes while keeping your view open.

Brick Top + Western — 45 degree viewBrick Top + Western — straight on viewBrick Top + Western — side viewBrick Top + Western — top view

Brick Top + Western

Crown: Brick
Brim: 4 ½" (Front: 7 ¼, Sides: 3 ½")

Square, tall, and commanding. The flat-topped Brick crease adds bold vertical presence, set on a classic swept 4 ½" Western brim.

RCA + Western  — 45 degree viewRCA + Western  — straight on viewRCA + Western  — side viewRCA + Western  — top view

RCA + Western 

Crown: RCA
Brim: 4 ¼" (Front: 10, Sides: 3 ¼")

Inspired by classic Rodeo Cowboys of America creasework. Features a tall front profile, sharp side creases, and a pronounced front-and-side brim rake.

Texas Punch (w/ Snake Eyes) + Texas Punch  — 45 degree viewTexas Punch (w/ Snake Eyes) + Texas Punch  — straight on viewTexas Punch (w/ Snake Eyes) + Texas Punch  — side viewTexas Punch (w/ Snake Eyes) + Texas Punch  — top view

Texas Punch (w/ Snake Eyes) + Texas Punch 

Crown: Texas Punch
Brim: 4 ½" (Front: 8, Sides: 3)

A classic working ranch build featuring distinctive side "snake eye" dimples on the crown crease, set on a 4 ½" brim with tight sides.

Gus + Rancher — 45 degree viewGus + Rancher — straight on viewGus + Rancher — side viewGus + Rancher — top view

Gus + Rancher

Crown: Gus
Brim: Brim: 4 ½" (Front: 5 ½, Sides: 4)

High in the back with a steep forward slope. The iconic Gus crown delivers maximum sun protection and timeless trail heritage, paired here with a broad Rancher brim.

MSC + Western — 45 degree viewMSC + Western — straight on viewMSC + Western — side viewMSC + Western — top view

MSC + Western

Crown: MSC
Brim: 4 ½" (Front: 9, Sides: 3 ¾")

A custom ranch shape engineered for long days in the saddle. Features deep side dents with a classic 4 ½" Western brim.

Telescope (Blocked) + Flat — 45 degree viewTelescope (Blocked) + Flat — straight on viewTelescope (Blocked) + Flat — side viewTelescope (Blocked) + Flat — top view

Telescope (Blocked) + Flat

Crown: Telescope
Brim: 4 ¼" Flat

Crisp, precision-blocked telescope top paired with a clean 4 ¼" flat brim. Delivers a sharp, modern silhouette with classic buckaroo roots and low-profile structure.

Pinch Front (Blocked) + Western  — 45 degree viewPinch Front (Blocked) + Western  — straight on viewPinch Front (Blocked) + Western  — side viewPinch Front (Blocked) + Western  — top view

Pinch Front (Blocked) + Western 

Crown: Pinch Front
Brim: 4 ½" (Front: 6, Sides: 3 ¾")

A sharp, modern crossover profile. Features a narrow front pinch on the crown that flatters narrower face shapes, set on a classic Western brim.

Keenland (By Hand) + Buckaroo  — 45 degree viewKeenland (By Hand) + Buckaroo  — straight on viewKeenland (By Hand) + Buckaroo  — side viewKeenland (By Hand) + Buckaroo  — top view

Keenland (By Hand) + Buckaroo 

Crown: Keenland
Brim: 4 ¼" (Buckaroo Roll)

Hand-creased for organic, soft lines. Combines a dressier Keenland crown contour with a sharp Buckaroo brim roll.

Telescope + Buckaroo — 45 degree viewTelescope + Buckaroo — straight on viewTelescope + Buckaroo — side viewTelescope + Buckaroo — top view

Telescope + Buckaroo

Crown: Telescope
Brim: 4 ¼" (Buckaroo Roll)

A uniform round telescoping crown paired with a crisp 4 ½" Buckaroo brim roll. Combines a sleek, low-profile crown with a traditional Buckaroo brim style.