When we set out to make a baseball cap in England, we searched the length of the country for a manufacturer without any luck. After speaking to the remaining hat makers that we found, we settled on a factory that’s been producing hats for over a Century.
Specialising in traditional styles, it was new territory for us both. It took eighteen months and numerous samples before we were happy with the fit and construction of the cap. This factory now produces these caps exclusively with us, making these some of the only baseball caps produced in the UK.
Each cap starts off life in the cutting room. As the cap is symmetrical, the fabric is doubled over and three knives are used to cut the six panels that form the crown.
To ensure that the weave of the fabric is aligned from one panel to the next, each hat is cut individually by hand.
The fabric is lined with a black satin and piece by piece, the six panels are sewn together to form the crown. Excess fabric is cut away and then each seam is run through a tape machine – neatening and securing any loose edges.
The crescent shaped fabric that covers two sides of the peak are sewn together inside out, trimmed and then turned the correct way around.
The fabric is stretched over a reinforced peak and then sewn closed. Four lines of stitching follow the outer line of the cap, holding the fabric in place.
The leather buckles are hand finished to our specification in London. The leather is tanned in Belgium using vegetable dyes – the most environmentally friendly method known. The edges are painted using an ink designed to seal the leather. The buckle is sourced from Italy.
A disc of fabric is cut and pressed using a hand stamp to form the button that sits at the top of the crown, where the seams intersect.
Our signature monogram rivet is the last detail to be added, positioned over the wearer’s left eye.
Finally, the cap is taken downstairs to the shaping room in which some of the newest machines are over half a century old.
The crown is sat over a jet of steam, softening the fabric before being placed on a heated mould. The cap is smoothed and worked by hand into the perfect shape.