How to Make a Hat Stretcher

Written by will litton
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A well-fitting hat is an ideal accent to any suit of clothes. But sometimes the perfect hat doesn't quite fit and needs to be stretched. Finding the right-sized hat stretcher can be difficult. Make your own hat stretcher and you can stretch your hats to exactly your size.

Skill level:

Things you need

  • Slab of wood
  • Table saw
  • Skin moisturiser
  • Small galvanised pipe
  • Electric drill

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  1. 1

    Measure the sweat band of your hat and trace it onto a slab of wood. Trace two crescent moon shapes that will press along the front and back of the hat's inside lip.

  2. 2

    Saw the crescent moon shapes out of the wood with a table saw. Tilt the blade slightly for better curvature.

  3. 3

    Sand the two crescent moon pieces of wood until smoothly rounded. Rub skin moisturiser into the wood to soften.

  4. 4

    Place the crescent moon shapes into the lip of your hat and measure out a length of galvanised pipe to connect them at a width that will stretch your hat to your desired hat size.

  5. 5

    Cut the galvanised pipe to size. Drill holes in the crescent moon wood pieces to accommodate the pipe.

  6. 6

    Join the wood pieces with the length of pipe and insert the hat stretcher into your hat. Lengthen the pipe as needed.

Tips and warnings

  • A softer wood, such as maple, works best.
  • If you stretch your hat too far, it might tear.

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