Custom Cowboy Hats
Handmade in Bozeman, Montana
Built one at a time around your head shape, personal style, and how you intend to wear it
Your deposit reserves your place in our build schedule and applies toward the final price of your hat.
Prefer to talk it through first? Call us at 406-587-7809.
A Hat Made for Your Head
Hat size tells us how big your head is. It doesn’t tell us what shape it is.
Two people can measure the same circumference and need very different hats.
A round head, long oval head, or asymmetry can all change how a hat feels and how it sits.
For every Rocky Mountain custom hat, we capture both your head circumference and individual head shape, then use that profile when blocking and fitting your hat.
The result is a hat built to sit naturally on your head—not simply one made to a standard size.
Visit us in Bozeman, use our measuring kit from home, or reorder from a fit already on file.
How Your Custom Hat Comes Together
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1. Reserve Your Build
Choose your felt and place your deposit to reserve a place in our production schedule.
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2. Get Measured
Visit us in Bozeman, use our measuring kit at home, or reorder from a fit already on file.
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3. Design Your Hat
Choose your crown, brim, color, ribbon, sweatband, liner, and finishing details online or with us by phone.
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4. We Build It
Your hat is blocked, shaped, trimmed, and finished by hand in our Bozeman shop, then shipped or fitted in person.
Choose Your Felt
For decades, we’ve worked closely with trusted felt makers to source hat bodies that meet our standards for durability, weather resistance, consistency, and value. These are proven felts we know well—materials we’ve shaped, worn, repaired, and relied on for years.
Our 50% and 100% beaver custom hats are built for customers who want an exceptionally well-fitting, hard-wearing hat made to be used for decades.
CUSTOM FELT
50% Beaver
A durable, premium fur felt with excellent shape retention and weather resistance. An outstanding choice for a custom hat intended for regular wear.
CUSTOM FELT
100% Beaver
A denser, finer felt with increased weather resistance, longevity, and refinement. Our highest-grade felt in the traditional Rocky Mountain custom line.
Not sure which is right for you? Choose “Not Sure — Help Me Choose” when placing your deposit and we’ll walk you through it.
Design a Hat That’s Yours
You don’t need to know the name of every crown shape, brim profile, or finishing detail before you begin.
Choose from our established styles, send us a reference photo, or simply describe the hat you have in mind. We’ll help translate that into the right proportions and details.
Crown shape
Cattleman, Gus, Brick, Pinch, Open Crown, and more.
Brim shape and width
From traditional western profiles to cleaner, more understated shapes.
Felt color
Selected from our available custom felt colors.
Finishing details
Ribbon, sweatband, liner, and the small details that make the hat distinctly yours.
After placing your deposit, complete the design online or work through it with us by phone.
A Custom Fit, Wherever You Are
You don’t have to visit Bozeman to order a properly fitted Rocky Mountain custom hat.
If you choose our measuring kit, we’ll ship the tools and instructions you need to capture your fit from home. Once your measurements are returned, we use them to create the head profile your hat will be built around.
If you’ve ordered a custom hat from us before, we may already have your fit on file.
Visit Us in Bozeman
We’ll measure you in person and talk through your hat at the shop.
Use Our Measuring Kit
We ship the kit to you, you complete the fitting at home, and send it back to us.
Fit Already on File
Returning customers can often reorder without repeating the measuring process.
The goal is the same either way: a hat built around your actual head shape, not just a standard size.
Custom Hat Pricing
Every custom hat starts with the felt body, your individual fit, shaping, and a standard 2-ply ribbon. Additional finishing details can be selected during the design process.
CUSTOM FELT
50% Beaver
Includes custom fitting, shaping, sweatband, liner, and standard 2-ply ribbon.
CUSTOM FELT
100% Beaver
Includes custom fitting, shaping, sweatband, liner, and standard 2-ply ribbon.
Ribbon & Edge Details
Hatbands
Other Details
Deposits are applied toward the final price of your hat. The remaining balance is due at pickup or before your completed hat ships. Final pricing is confirmed once your design details are selected.
Handmade in Bozeman Since 1990
For more than three decades and across three generations of the Morris family, Rocky Mountain Hat Company has built custom hats one at a time in Montana.
What began as a family craft has been carried forward through decades of hands-on hatmaking, fitting, shaping, repair, and refinement.
Each custom hat is blocked, shaped, fitted, trimmed, and finished in our Bozeman shop using tools and techniques developed over generations of hatmaking.
Your hat begins with your individual head profile and is finished around how you want it to look, fit, and wear.
A well-made custom hat should become more personal with age—not disposable with wear.
Three Morris family generations. Built here. Fit to you. Made to be worn for years
Built to Be Worn
A few words from customers who have experienced Rocky Mountain Hat Company firsthand.
“Amazing customer service! John has so much knowledge to offer and we really felt like we were in good hands.”
“Fantastic service, very knowledgeable and creative with our hat requirement. Anytime again! Great selection of hats.”
“John was amazing. Definitely a learning experience! Beautiful hand crafted hats made to last!”
ROCKY MOUNTAIN HAT COMPANY
Ready to Start Your Custom Hat?
Reserve your place in our build schedule today. Once your deposit is placed, we’ll guide you through fitting, design, and every detail needed to build a hat specifically for you.
Prefer to talk it through first? Call us at 406-587-7809