All About Stetson Hats: History, Styles, How It's Made & Reviews

The cowboy hat, with its high crown and wide brim, is more than just a hat—it's a symbol of the North American cowboy.

Since its creation in 1865 by John B. Stetson, the iconic cowboy hat has stood the test of time, maintaining its distinctive design and construction. Not just a fashion statement, this hat's unique shape, which can usually be adjusted, serves a practical purpose too.

It's made to shield against the elements, whether it's the blazing sun or a heavy downpour. The cowboy hat remains a timeless piece, unchanged since its invention by John B. Stetson in the 1860s, and continues to be a hallmark of cowboy culture and style.

Here you'll find out how to decide which style of Stetson hat is right for you, where they're made, the history of Stetson hats, the El Presidente 100X Premier Cowboy Hat, and what the reviews say about Stetson hats.

Stetson Hats

Stetson hats aren't just a brand; it's a statement of timeless elegance and rugged durability. Whether you're a cowboy through and through or a fashion-forward urbanite, there's a Stetson hat with your name on it.

What's In A Stetson Hat?

There are several key parts to a cowboy hat.

• Crown: This is the top part of the hat which covers the head. The height and shape of the crown can vary, with some common styles being the Cattleman, the Pinch Front, and the Gus. The crown's shape can influence both the style and the fit of the hat.

• Brim: The brim is the wide, flat piece that extends out from the base of the crown. It provides shade and protection from the sun and elements. Brims can be shaped to different styles, such as flat, turned up at the sides, or curved.

• Band (or Hatband): This is a decorative band that wraps around the base of the crown. It can be made of leather, ribbon, or other materials and may include decorative elements like buckles, feathers, or pins.

• Sweatband: Located inside the hat, the sweatband is typically made of leather or fabric. It helps the hat fit securely and comfortably while absorbing sweat.

• Sizel;: Proper sizing is crucial for comfort. Cowboy hats are typically measured in inches or hat sizes. It's important to measure your head circumference to ensure a proper fit.

• Color: Cowboy hats come in a range of colors. Traditional colors include black, white, brown, and tan, but they can be found in various other colors as well.

• Crease: The crease on the crown of the hat can vary and often signifies different styles or regions. For example, the Cattleman crease is a classic and very popular style.

• Material: Cowboy hats can be made from various materials, including felt (often wool or fur), straw, or leather. Felt hats are generally warmer and more durable, ideal for cooler weather, while straw hats are lighter and more breathable, making them better for hot weather. Stetson uses the "X" rating to indicate quality of fur felt.

Material and the "X" Factor in Stetson Hats

Stetson has a unique rating system for felt quality.

• Felt Quality: Stetson hats, especially those made of felt, often come with an "X" rating. This "X" factor is an indication of the quality of the material used, specifically the amount and fineness of the fur used in creating the felt. Traditionally, this fur comes from animals like beaver, rabbit, or wild hare, and sometimes a blend of these.

• Higher X Rating Equals Higher Quality: The higher the X rating, the higher the quality of the hat. Higher X-rated hats are typically made with a greater proportion of beaver fur, which is finer and more durable, making the hat softer, more luxurious, and more water-resistant.

• Impact on Price: The X rating also affects the price of the hat. Generally, as the X rating increases, so does the price, due to the improved quality and durability of the materials used.

JBS Heritage Stetson Hat

The JBS Heritage Stetson hat is a classic 6X fur cowboy hat, handmade from premium quality 6X fur felt. It is a part of Stetson's New Frontiers Collection and features a 4 5/8" cattleman crown.

The X rating on the hat indicates the quality of the fur felt, with a higher number of X's representing a higher quality.

The JBS Heritage Stetson hat is a prime example of Stetson's high-quality craftsmanship and is a true American classic, reflecting the brand's legacy as an American heritage brand since 1865

Top Reviews

"My first ever Stetson cowboy hat is nothing short of stunning. With just a bit of steaming, it shaped up to fit me flawlessly, just in time for the chilly season. It’s needless to say, but this hat is the finest in my collection. A big thank you for the seamless delivery and the meticulous care in shipping. I'm over the moon with my new hat!"

"This Stetson hat is the epitome of quality craftsmanship. It's a handsome piece, but be prepared for a bit of a break-in period. It's like a pair of premium shoes; it takes some time to mold and adjust to your shape. Wear it often, let it weather a few storms, and before you know it, it'll fit like a glove. Trust me, you'll find yourself not wanting to take it off."

Skyline Stetson Hat

The Stetson Skyline hat is a part of Stetson's New Frontiers Collection and is crafted from their proprietary 6X fur felt, known for its durability and elegant feel.

It features a 4 5/8" cattleman crown and a 4" brim, giving it a classic Western style. The hat is handmade in the USA and is designed to be durable, reflecting Stetson's legacy as an American heritage brand since 1865.

The Skyline hat is available in differnt colors and is finished with a matching self-felt band and a three-piece, silver-tone buckle, adding a touch of practical elegance to its design.

Top Reviews

"I'm thoroughly impressed with this hat. It's a genuine 6x western firm felt piece with a stylish leather band. The fit? Spot-on, consistent with my other Stetsons, and it comfortably molded to my head within a few hours. The color pleasantly surprised me. I was expecting a pinkish-white hue, but it's more of a subtle beige, which I adore. The packaging was top-notch, arriving in a Stetson hat box, further secured in an outer box. Absolutely no problems whatsoever. If you're considering it, don't second-guess yourself. It's a purchase you'll definitely be happy with."

"This Stetson is an exceptional hat. The felt is both soft and lightweight, and it fits perfectly, as long as you get your size right."

Tom Mix Stetson Hat

The Stetson Tom Mix hat is a tribute to the legendary cowboy actor Tom Mix, known for his daring stunts and iconic Western style.

Handcrafted in Texas from resilient 6X fur felt, this hat features a distinctive 4 ½” to 6 ½” sloped Gus crown and a 5” bound-edge brim, reflecting the bold, archival Western profile made famous by the Hollywood legend.

It is finished with a wide grosgrain hat band, a branding-iron hat pin bearing the initials "JBS," a genuine leather sweatband, and a full satin liner, ensuring both durability and comfort.

Top Reviews

"Many years back, as a young Marine 1st Lieutenant attending an Army school in Arizona, I acquired my first Tom Mix hat. It quickly became my go-to party hat, the kind that seemed to give me a free pass to fun and mischief. In a moment of what I thought was generosity, and a bid to turn over a new leaf, I handed it over to a pediatric dentist known for his quirky choice of headwear. Fast forward 48 years, and I've finally got my hands on my second Tom Mix. This time, it's a keeper. Every time I wear it, the compliments roll in, and I'd wager at least half are sincere."

Royal Flush Stetson Hat

The Stetson Royal Flush is a versatile hat available in both fur felt and straw materials, featuring different crown and brim dimensions. The fur felt version is part of the Stetson Gun Club Collection and is made from high-quality rabbit fur felt, with a variety of crown and brim sizes.

On the other hand, the straw version is a 10X Shantung cowboy hat with a 3" brim and a 3 7/8" crown. Both versions reflect Stetson's commitment to quality and offer a classic Western style, making them suitable for various occasions and preferences.

Top Reviews

"My husband is on his third one now, and he absolutely adores it. He's always receiving compliments, which speaks volumes. What else is there to say? It's genuinely a great buy, both in terms of quality and price."

"I'm a 7 1/4 in hat size, and that's exactly what I ordered. The fit? Spot on. It's comfortably snug, staying put without any fuss. This is my third Stetson, and their quality never ceases to amaze me. I own a 6X in black which is more suited for formal occasions, but this one? It's ideal for my intended uses – fly fishing, hunting, and various other outdoor pursuits. I scored this Stetson at an exceptional price, and the value for money in terms of fit, style, and quality is outstanding. This hat, in a unique stone color, is not only striking but also built for rugged use. I don't plan to coddle it, fully expecting it to live up to the Stetson legacy. Overall, I'm thoroughly impressed with this hat and anticipate many years of use. I highly recommend it – it's a Stetson that truly offers more than what it costs. An exemplary piece of craftsmanship!"

El Presidente 100X Premier Cowboy Hat

The Stetson El Presidente is a part of Stetson's Premier Collection, made from premium 100X fur felt, showcasing the legendary craftsmanship the brand is known for.

This high-quality cowboy hat features classic cattleman hat styling, with a tall crown and a 4” to 4.25” wide brim, depending on the specific model. It is handcrafted in the U.S.A. and comes with a soft, satin-lined crown, a comfortable 2” leather sweatband, and a self-felt hatband dyed to match the body of the hat.

This Stetson hat is finished with a 3-piece 10K gold buckle set on the self hat band, adding a touch of luxury to its design. The El Presidente is a symbol of class and luxury, reflecting Stetson's enduring legacy and commitment to quality, making it a timeless and iconic piece in the world of Western fashion.

Why Do Cowboys Wear Stetson Hats?

Cowboys wear Stetson hats because they protect his face from the elements, are very durable, and have become a symbol of Western culture. 

History of Stetson Hats

The history of Stetson hats all began with John Batterson Stetson, born in 1830 in East Orange, New Jersey, into a family of hatmakers. His father ran the successful No Name Hat Company, where young John B. learned the trade.

But, after he received a terminal diagnosis of tuberculosis, he decided to live out his days on the American frontier during the Colorado Gold Rush.

So, in the early 1860s, John B. Stetson ventured to Pike's Peak to find gold. During this time, he and his companions were exposed to rainstorms, harsh winds, and intense sunlight.

Stetson had an idea.

He used a primitive felting technique and crafted a waterproof blanket out of animal fur, this became the first 'Boss of the Plains' hat.

But at first, his companions laughed at Stetson. But soon, they saw that the hat not only served as protection from the rain, sun, and wind, it could also be used to water your horse in a pinch.

Prospectors started buying Stetson's hats for a $5 gold coin and their popularity skyrocketed.

Stetson knew he was onto something.

In 1865, after his health improved and he didn't find any gold, Stetson headed to Philadelphia. He used a $60 loan from his sister to start his own hat manufacturing business. He found a small workshop, hired 2 employees, and bought as much material as he could afford.

To get the word out about his "Boss of the Plains" hat, Stetson mailed a free hat to dealers in the Southwest and asked them to buy a dozen if they liked it. Many of them did, and Stetson's business was off the ground.

By the early twentieth century, Stetson owned the world's largest hat factory, with international sales, 1,200 workers, and more than 50,000 hats a year. He treated his employees well, starting one of the first healthcare initiatives and education programs.

Even famous celebrities of the time loved Stetson hats.

John B. Stetson passed away in 1906, but it didn't stop the growth of his company, or his legacy as a humanitarian and innovative business leader.

By 1915, the factory had expanded to 25 buildings with 5,400 employees producing over 3 million hats annually.

Stetson hats were a favorite of many, including senators, presidents, and Hollywood stars like Tom Mix, who became an unofficial brand ambassador.

Stetson began producing women's hats in 1930, expanding their range to include berets, pillboxes, and tricornes.

In the 1940s, the Stetson line included straw boaters, panamas, trilbys, and various ladies hats, cementing its place as a must-have accessory. A hat was a requirement for any upstanding citizen in American.

But in 1960, everything changed. Newly elected John F. Kennedy delivered his innaugural speech hatless. This spread a message across America that hats weren't required and demoted them to an optional accessory.

Despite this, Stetson survived, and much of their survival is because they went back to basics, and started focusing on their widely popular Stetson cowboy hat.

In 1970, Stetson transitioned from manufacturing to licensing and closed their factory, marking a new era for the Stetson company.

When the 1980s arrived, the Western hat business saw a resurgence, fueled by movies like Indiana Jones and Urban Cowboy.

Stetson continues to innovate through the years. They are involved in sports,, music, and continue to produce the high quality cowboy hats they started with.

Throughout its history, Stetson has remained a symbol of quality, style, and American spirit, adapting to changing times while maintaining its core values and heritage​​.

What Is The Story Behind The Stetson Hat?

The story behind the Stetson hat company begins in 1860 with John B. Stetson who left New Jersey after being diagnosed with terminal tuberculosis to participate in the Colorado Gold Rush.

While braving the elements, he was inspired to create the first Stetson hat, which became known as the "Boss of the Plains," to protect himself from the rain, wind, and sun. This hat even served as a makeshift water bucket for his horse.

How Stetson Hats are Made

The creation of a Stetson hat is a fascinating blend of art and craftsmanship. These iconic hats start their journey with high-quality furs like beaver, rabbit, and wild hare.

First, the furs are thoroughly cleaned to strip away any impurities. This paves the way for the felting process, where the magic really begins. Hot water and dyes come into play here, transforming the furs into the felt that forms the heart of every Stetson hat.

But that's just the beginning. The felt then undergoes softening, using a special powder, and starts taking the shape of a hat. This involves meticulous steps of forming the crown and the brim – the parts that give a Stetson its signature look.

Once the basic shape is ready, the hats are treated with shellac, dried, and undergo a final shaping. This includes adding a dent in the crown and curving the brim to perfection.

Every Stetson hat is then sanded down, compacted, and undergoes a thorough inspection. This ensures each hat meets the high-quality standards the brand is known for.

The finishing touches are crucial – a genuine leather sweatband for comfort, a smooth satin lining, and, of course, the iconic Stetson image inside the crown, symbolizing authenticity and craftsmanship.

The hats are not just about the felt; they also feature leather in the interior sweatband and a ribbon around the crown, often made from a two-ply or two-cord band. Small metal eyelets are added for venting, ensuring comfort and practicality.

The distinctive style of a Stetson hat comes from the unique slope of its crown, the roll of its brim, and the specific arrangement of creases or pinches in the crown.

These elements together create the unmistakable Stetson look.

In making these hats, Stetson seamlessly combines traditional handcrafting techniques with modern methods. The company takes pride in the quality and detail of each hat, crafted in their dedicated facilities. From shaping to adding the final touches, every Stetson hat reflects a commitment to excellence and a legacy of enduring style.

Where are Stetson Hats made?

Stetson hats are proudly made 30 minutes east of Dallas, Texas, USA.  

Originally made in Philadelphia, the production later moved to St. Joseph, Missouri, and then to Texas​​. The Stetson factory is nestled in a peaceful neighborhood, just about 30 minutes east of Dallas, Texas. 

This factory is where the magic happens, producing a wide variety of Stetson hats including classic fedoras, elegant Panama hats, iconic cowboy hats, and stylish newsboys.

The process of making these hats is steeped in tradition and has remained largely the same for over a century. Not far from the main factory is another important site: a felt factory. Here, Stetson crafts the unshaped hat shells, using high-quality materials like beaver, rabbit, and wild hare fur.

Each Stetson hat is a product of meticulous craftsmanship. Made one at a time, these hats are not just pieces of fashion; they are embodiments of American craftsmanship and quality. This commitment to handmaking each hat is a significant part of what gives Stetson hats their well-earned reputation for being long-lasting and stylish.

The Stetson brand, as confirmed by their website and other sources, is a testament to a longstanding tradition of American craftsmanship. Each hat is a piece of American heritage, crafted with care and pride, right here in the U.S.A.

What Is The Difference Between A Cowboy Hat And A Stetson?

A cowboy hat and a Stetson are different because the Stetson hat is a classic cowboy hat, known for its wide brim and high crown. The crown is often creased, and the brim is often rolled.

Why are Stetsons So Expensive?

Stetsons are expensive due to their high-quality materials, craftsmanship, and status as a symbol of American heritage and Western culture​​. A Stetson hat will last for years and years.

Final Thoughts

The Stetson cowboy hat is not just a piece of headwear; it's a cultural icon, embodying the spirit of the American West. Its enduring popularity since John B. Stetson first introduced the "Boss of the Plains" model in 1865 is a testament to its timeless design, practical functionality, and the unwavering commitment to quality that Stetson has maintained for over a century.

The distinct features of a Stetson – from the high crown and wide brim to the unique "X" rating system indicating the quality of fur felt – contribute to its status as a desirable accessory for both the fashion-conscious and the practical outdoorsman. The various styles, from the JBS Heritage to the Tom Mix, offer something for every preference, ensuring that owning a Stetson is as much about personal expression as it is about utility.

Whether it's worn for protection against the elements, as a fashion statement, or as a symbol of a proud heritage, a Stetson hat carries with it a history of American craftsmanship and an enduring legacy of rugged elegance. The reviews of those who have donned these iconic hats echo this sentiment, highlighting their quality, durability, and the sense of identity they impart.

In an era where the pace of change is relentless, the Stetson hat stands firm, a steadfast reminder of enduring values and timeless style. It's not just a hat; it's a piece of history, a work of art, and a badge of honor for those who wear it. Whether you're a lifelong cowboy, an enthusiast of Western style, or someone who appreciates the finer things in life, a Stetson hat is more than an accessory – it's a statement, a legacy, and a treasured heirloom for generations to come.

Richard Sutherland

RichardSutherland@bitsnspurs.org

Richard is a western lifestyle author for Bits N' Spurs, the weekly newsletter that keeps pace with today's rodeo. His articles are featured on dozens of rodeo and Western related websites and provide a window to the world of cowboy culture.