OK ... you've got me interested! I think I'm going to make this thing for my wife and me. It's a great looking and functional hat.
I have one question right off the bat, but I'm sure there will be more to follow. What do you use for the "wire" to stiffen the brim? What material and what guage did you use?
I have a Tilley and a Pacific Dorfman wool "cowboy" style hat. I have inpected them and they do not have a wire. They are also packable, which is a very important characteristic! I crush these hats into my backpack or luggage and they pop out in amazingly good shape. with a minute of tugging on them, they look as if they have never been folded.
I would seem to me that a metal wire wouldn't be this resilient; that it would permanently bend out of shape. Also, with many manual bendings to reshape the brim, it would seem that the metal would break from fatigue failure.
I'm looking for some guidance here, help!