Forging a Cowboy Hat.mpg

See how a blacksmith forges a cowboy hat.

[@tomcoker9882]

Very nice demo Dave, with great step by step explanations. Bev has been trying her hand at it after you demoed it at Tuckahoe. Cheers, Tom

[@teddharris]

Wow! Gotta try this! Love your demonstration. Thanks!

[@scarfing]

What a great demo! Thank you for sharing this.

[@MrOldclunker]

A very good instructional video. I appreciate your taking the time to show us. Thanks again.

[@christopherneelyakagoattmo6078]

So cool. Hammer-dashery.

[@kurnous34]

hey neat concept, first time ive seen one of these on youtube

[@gateway8833]

Sir, you are so talented, I will be able to copy this item but I will give your name as designer.

[@ArtistBlade1972]

What was the diameter of the blank you used in the video? The bottom swage also?

[@HWPcville]

I was wondering about the size of your rawhide mallet (weight & face diameter). No stores carries them locally so I will have to order online and I don't want one that's too small/light or too large/heavy. Do you have a preference, or do you wish your's was heavier or lighter? I've collected all the tools necessary to make a hat except for the mallet. Thanks for posting this interesting and informative video.

[@HammerMan999]

I make many sizes of hats, from small enough to be used for ear rings to up to about 11 inches in diameter, so I have several sizes of leather mallets I use. For the hat in the video, a mallet of about 2 inches in diameter (about 12 ounces total weight) was used. A slightly smaller mallet could have been used also. I have them down to 1 inch diameter and up to about 3 inches in diameter. I generally don't worry about weight. Leather mallets are fairly expensive to buy new. I watch for them at tailgate or yard sales and usually can buy them for just a few dollars. They can easily be cleaned up (or reshaped) on a belt sander. Don't bear down too hard or you will burn it. If you can't find one for a reasonable price, a wooden mallet would work also... and that you can make yourself. One time I was demonstrating and I forgot to bring my mallet. I successfully used a short length of a tree branch a couple inches in diameter (firewood). The goal is just NOT to put marks on the hat when shaping it. Good luck, and thanks for watching my videos..

[@HWPcville]

Do you have a recommendation for a replacement to the lubricating salt you use? I tried my hand (admittedly with too thin metal) but with no lubrication and it more or less started to punch a hole in the metal. You said the product you use is no longer available? Thanks!

[@HammerMan999]

I haven't tried it, but I've read that the following makes a lube blacksmiths can use. One pint of water, 2 tablespoons of dish soap (like Dawn) and stir in table salt until saturation (about 1/4 cup). Another lube suggestion is a bit more complicated (and most likely better)... This one is attributed to Uri Hofi. Equal parts of molybdemum and graphite powder, mixed with dishwashing soap and some water to the consistency you like (thick enough to hang onto a tool). Molybdenum disulphide (MoS2). Moly can be ordered from gun smithing suppliers and I'm sure other places. Graphite can be bought at art stores. Take two soup spoons of each powder, graphite and Moly, and mix together. Add liquid dishwashing soap (like Dawn) until it forms a paste. Transfer this paste to a larger container. Add water to make about a pint of solution (mix well). Dip the tool, or brush the lube on the tool. Stir frequently to prevent settling. Keep in a sealed can when not in use. When I make a hat the size of the one in the video, the sheet metal is usually about 1/8th of an inch thick (sometimes thicker). It can be done with thinner metal, but it is more difficult. The problem is that the heat is drawn out too quickly and the metal will tear. The thinnest I have made a had that size was probably with metal thicker than a 16th of an inch (and it takes more heats). I believe it would be very difficult to make a hat, at least that size, with thinner metal using the method I show in the video. Good luck....

[@dickiegreen8531]

great video how do you determine punch size compared to hat dia thank you

[@HammerMan999]

I'm not sure what question you are asking... If your question is about size of the disc I start with.... as compared to what diameter the rim of the hat ends up.... The answer is..... It varies, depending upon the type of hat you want to make. Is the hat going to be tall? How wide do I want the brim? How much bending do you want to do on the brim? If I make a wide brim'd hat (Sombrero), with a small punch, the head part doesn't take much material, so the diameter of disc isn't affected much. If you want a big head hat with a small brim, it will probably pull in quite a bit. I've probably made 20 variations of hats. Some have wide brims (big cowboy hats), some have narrow (Derby). I don't have a formula I use.... I just experiment. If you want a guideline to start with, use a disc that is three times as wide as the ID of the die. See what you end up with and go from there... The end rim diameter will be affected by how far you drive the punch into the die. Find something you can use for the die (with the ID about the head size you want to have), then find (or make) a punch that will provide enough clearance to draw metal down into the die without getting stuck (with a little wiggle room)... . I use 3 times the thickness of the disc as the guideline for the difference between the diameter of the punch and the ID of the die. For example... If the ID of your die is 2 inches, and you are using 1/8th inch plate for the hat.... The punch should be about 1 5/8th inches in diameter. If you want the head to slope to the peak a little, use a slightly smaller punch. Use a 6" disk.... Punch it down until you are happy with the height for the head. This isn't rocket science... It's fun... so just experiment. 1/8" plate is cheap.... Especially if you can find a fabrication shop and can get into their scrap pile. Hope you are having fun making them....

[@dickiegreen8531]

David Hammer thanks for the reply I believe I was over thinking it but it make sense now thanks again

[@skullcollector29]

Sweet........!

[@bjornnjordson2986]

Now I've seen it all... A blacksmith making hats.

[@stevengrosz540]

I work wood also and I want to try a wooden cowboyhat on the lathe.

[@cinimatics]

steven grosz My great grandpa used to do that. I'd like to try it someday as well.

[@randybingham281]

Bjorn Njordson if

[@rayanderson5972]

David , how can i contact you ? I would love to add this to our winter schedule , and i have questions

[@7602416553]

Hi Dave It's me again oh yes buy the way where did you get your stamp from????????????? Would like to buy one!

[@7602416553]

Hi Dave Hey I made a forge like the one you use and the orifice and pipe that I seen you make I'm having trouble from keeping it to spitting and sputtering can you maybe help me with adjustment on the orifice and why cant I get my metal hotter than it gets...I cant get my heat to wheat or white, I'm learning also but having trouble so please help or maybe you can call me...

[@yaronfirelord9604]

wud you make a mans head sized metal cowboy hat??

[@HammerMan999]

Yaron FireLord The largest had I've made was with an 11" disc. I could make a full sized hat, but I expect it would have to be forged using a hydraulic press. Maybe someday.

[@yaronfirelord9604]

i can't wait to see that :)

[@yaronfirelord9604]

and the 11" disk hat is for a little boy size right???