PM-26-011 – 100% Beaver Pork Pie

Finished gray 100% beaver felt pork pie hat with black ribbon and bow, Project PM-26-011, made at the Walton hat-making workshop.

Project Summary

ProjectPM-26-011
CompletedOctober 2026
WorkshopWalton, Kentucky
Material100% Beaver Fur Felt, Western Weight (230 g)
StylePork Pie
Size60 cm
Current CollectionPersonal Collection — Baton Rouge, Louisiana

PM-26-011 is a 100% beaver pork pie completed during the October 2026 hat-making workshop in Walton, Kentucky. Built from a western-weight 230 g beaver fur felt body, the hat became one of the first hats completed during formal hands-on training.

From Felt Body to Finished Hat

Blocking

The felt body was first prepared and pulled over the crown block to establish the basic size and form. Care was taken to seat the body evenly on the block before the brim was set for the next stages of construction.

Preparing the 100% beaver felt body for blocking with steam during the Walton hat-making workshop.
Pulling the beaver felt body down over the hat block during blocking of Project PM-26-011.
Working the felt body down onto the crown block during the blocking process for PM-26-011.
Setting the brim break with blocking cord and a pusher downer during construction of Project PM-26-011.

Pouncing and Firing

After blocking, the felt was pounced to refine the surface, remove irregularities, and begin developing the final finish. This stage was worked progressively and carefully to even the felt without taking off more material than necessary. Firing was used to balance out the Shellac.

Pouncing the crown of the 100% beaver felt body during construction of Project PM-26-011.
Working the surface of the blocked beaver felt during the pouncing stage of Project PM-26-011.
Firing the surface of the 100% beaver felt during finishing of Project PM-26-011.

Sweatband Preparation and Installation

The sweatband was prepared to size, joined, and then hand-sewn into the hat. This stage required careful placement so the band sat evenly inside the crown and supported the final fit of the hat.

Prepared leather sweatband for Project PM-26-011 showing The Workshop Ledger branding before installation.
Prepared leather sweatband for Project PM-26-011 showing the joined seam, decorative cross-stitching, and sweatband bow.
Installed leather sweatband inside Project PM-26-011 after hand sewing, showing the completed interior fit.

Brim Cutting

After the sweatband was installed, the brim was cut to the intended width and refined for an even edge before the final shaping and finishing stages.

Cutting the brim of the 100% beaver felt hat to its final width during construction of Project PM-26-011.

Ribbon, Trim, and Liner

The finished hat was trimmed with a grosgrain ribbon and bow, with the Maker’s Sword added as the final exterior signature detail. A liner was installed to complete the interior.

Installing the ribbon and trim on the 100% beaver pork pie during construction of Project PM-26-011.

After the ribbon and trim were installed, the crown and brim were shaped into the finished pork pie form. This stage established the final crown profile, brim attitude, and overall proportions of the hat, bringing the construction together into its completed shape.

Finished Hat

Finished gray 100% beaver pork pie with black grosgrain ribbon, bow, and Maker’s Sword, Project PM-26-011.
Front view of the finished gray 100% beaver pork pie showing the crown profile, brim, and black grosgrain hatband.
Top view of the finished 100% beaver pork pie showing the tear drop telescope shaped crown and brim of Project PM-26-011.
Interior of Project PM-26-011 showing the leather sweatband, decorative seam and bow, and patterned liner.
Finished gray 100% beaver pork pie worn outdoors after completion of Project PM-26-011.

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