Movie Hats

Movie Inspired Custom Handmade Hats

by Bernard Hats

Unleash Your Wild West Spirit with our Outlaw Josey Wales Custom Handmade Cowboy Hat

Our Josey Wales custom handmade cowboy hat is the perfect accessory for fans of western frontier fashion and film.

The Outlaw Josey Wales

Film fans and western fashion aficionados alike will be drawn to our Outlaw Josey Wales Custom Handmade Cowboy Hat.

This high-quality fur felt hat pays homage to the legendary western frontier hero, Josey Wales. Designed with a bound brim edge and a satin ribbon hat band, the hat features a cavalry cord which is customizable in white, yellow, black, or red.

Capturing the rugged western aura of Josey Wales, the hat can be ordered with a soiling effect, offering an authentic aged appearance. The hat design features a slight front pinch, a Pecan top, and a 1/2″ kettle curl bound brim. The 1″ satin ribbon hatband is adorned with a cavalry cord, adding to its frontier appeal.

The hat color as shown is bone, but can be customized further with optional heavy soiling. With its slight front pinch, Pecan top, 1/2″ Kettle Curl Bound brim, 1″ satin ribbon hatband with a Cavalry Cord, and customizable color options, this hat is more than just an accessory.

Unleash your wild west spirit and make a statement with the Outlaw Josey Wales custom handmade cowboy hat.

Experience the magic of cinema and the rugged charm of the western frontier with this iconic cowboy accessory.

The Outlaw Josey Wales Custom Handmade Cowboy Hat

The Outlaw Josey Wales Custom Handmade Cowboy Hat


Live your wild west dreams with our Outlaw Josey Wales handmade fur felt cowboy hat, inspired by the iconic film character.

SKU: ch-0005 Categories: ,
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About Our Movie Hats

We make custom hats so the crown and brim measurements are pretty much redundant.

The hats you see online are our standard hats, if you want a specific crown and brim height we will confirm that after your order is received. For a cowboy hat, we can make up to a six (6") inch crown and a five (5") brim. Any hat with a brim width of more than 4 inches we must start with an oversized hat body, which adds a little to the cost.

Most of our cowboy hats have a crown height between 5 and 6 inches and a brim width of 3 1/2 to 4 inches. Hat styles shown with a wider brim include The Wasey, Quigley, Everett Hitch, Blondie, Little J, The Dunson, Last of the Dogmen, Wild Bill, all our B-Movie hats, and many of our Custom Rodeo Hats


Black is a color signifying depth, mystery, and often associated with elegance and formality.


Charcoal grey is a dark, almost black shade of grey, reminiscent of the color of burnt wood.


Granite is a light color, ranging from white to pinkish grey, often speckled with black or brown


Chocolate is a rich, deep brown color that resembles the hue of dark, melted cocoa.


Pecan is a warm, medium-brown shade reminiscent of the rich, nutty hue of a pecan shell.


Whisky is a warm, mid-brown shade, inspired by the rich tones found in whisky.


Natural is a light cream or beige color. Note: Natural is only Available in 20x & 100x


Sahara is a warm, sandy beige hat color that evokes images of the vast, sunlit deserts.


Bone is a light, creamy white color, often compared to the shade of an animal bone.


Silver-Belly is a light, shimmering shade that resembles the color of polished silver.

Beaver Fur Felt for Custom Handmade Hats

Our Beaver Hats are made from high-quality felted beaver fur.

Beaver fur felt is a long-lasting, dense and nearly waterproof material made from a blend of beaver and/or rabbit/hare fur with felt. It is known for its exceptional durability, lasting 5-10 times longer than wool-felt. A high-quality hat made from Beaver and Beaver blend fur-felt can be easily reshaped multiple times using just a steam iron and some patience. This material is highly regarded for its ability to create top-notch hats.

Our Beaver Fur Felt

Ideally, a higher concentration of beaver fur should be indicated by a higher X factor. However, the hat-making industry lacks a standardized system, leading to confusion. Many hat sellers do not disclose the composition of their fur-felt, and some even misleadingly market straw hats as 100X. As a general rule, if a hat maker simply refers to their hat bodies as fur-felt, it is likely made from rabbit or hare fur.

We offer three quality beaver blends for our custom hats:

  • 5X blend consists of approximately 5% beaver combined with rabbit and felt.
  • 20X blend contains 50% beaver combined with rabbit and felt.
  • 100X is made from pure 100% beaver fur-felt.

For a hat that can withstand any weather conditions, a pure beaver cowboy hat is unbeatable. It is lightweight, rigid, and visually stunning, capable of repelling anything that comes its way. And remember, if you desire a water-resistant material, consider that beavers inhabit water while rabbits reside in the dirt.

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