This is a replica of the movie hat worn in Quigley Down Under. An outstanding hat from an outstanding movie. "Quigley Down Under" instantly became one of those iconic movies, and Tom Selleck created what we think was the best character of his career in Mathew Quigley. If you haven't seen it lately you should rush out and get the DVD. The story, the acting, the direction, the costuming, and hardware are all first rate. 7" Crown 5" Brim "Quigley Down Under" inspired a side match event at many Single Action Shooting events. Usually called the "Quigley Match". It is single shot buffalo rifle, off hand, at 200 yards or so. Tom Selleck should be proud. Tom Selleck's hat was also the best of his career, it suited him perfectly even though hats of this proportion actually became available a few years after this time period, but we wont worry about that detail. The style is similar to our 5 inch brim bull rider but not exactly the same. Notice the slightly different crown and brim; Our Quigley is exactly like that in the movie. We don't just adapt a preexisting hat to make an impression of the look, we form our hats by hand exactly like the original. Use the table below to determine your hat size based on your measurements.1. Material SourcingThe process begins with finding raw material. Optimo has a worldwide exclusive on sustainably sourced Canadian silver beaver felt from a supplier in Portugal and each year releases variouscolors and weights for limited-edition collections. Beaver is the ultimate fur to felt for a smooth-finish hat because of its tightness and feel, Thompson says. Traditionally, underbelly [fur] is known as the best of the best because the color is clearer and more vibrant once its dyed. The fine fur is felteda time-honored technique that binds the fibers together and produces a bell-shaped hat bodyat the mill before being shipped to Chicago.2. BlockingThe next step, called blocking, creates the initial structure. An inverted hat body is placed into a 1940s blocking machine that Thompson sourced from Germany. The material is then steamed, and a domed mold called a hat block is plunged into the felt, forcing it into the desired size and shape.3. Slow BakeThe blocked hat body is put through a secondary blocking, called decatizing, in which its steamed again and then slowly baked in a decatizing machine. I would liken it to a curing of the fabric, Thompson says. This process makes the felt more resistant to shrinkage and prevents the shape from being knocked out of it. Just to do that step is very expensive and requires a lot of additional molds.4. Rest and VacuumThe hat body is lined up on a rack and left to rest for a few days in a climate-controlled room before going to surface finishing. Most are finished smooth, the felt shaved with fine abrasive papers, as well as conditioned and polished. Finally, a high-suction machine vacuums any dust particles from the pores of the hat. A lot of the time you dont see the problems until you begin surface finishing, because theyre beneath the outer layer of felt thats being worked, explains Thompson. Those can be clumps of fibers that werent uniformly felted or color inconsistencies. Finding such flaws means the hat must be scrapped.5. TrimmingOnce the hat passes inspection, its off to the trimming room. Here, a sheepskin sweatband is snipped to size and installed with a vintage Singer sewing machine. (Thompson finds the older models to be of higher quality.) The brim is cut, and the edges are either welted, bound, curled, or, in some cases, left raw. The treatment affects not only the look but also how the brim snaps and holds.6. Ironing the BrimNext comes the flanging bench, where the headwear is flipped upside down into a donut-looking mold called a flangewhich corresponds to the desired size, brim width, and brim shapeand placed under a large, heated bag of sand. Its kind of an ingenious way to iron the brim, Thompson says. It sits under there for several minutes, and then we let it sufficiently cool.7. Satin LiningThe piece is returned to the trimming room, where a satin lining is sewn inside the crown and a ribbon and bow are secured to the outside. Most of our ribbon, we have specially produced for us, Thompson says. Were fortunate enough to have a lot of vintage ribbon that was made in the 1930s, 40s, and 50sthe quality was more refined then.8. Final TouchesLastly, the hat undergoes a secondary flanging before arriving at the hatters bench for final finishing, including creasing, polishing, and gentle steaming to relax the fibers and bring out the colors. Each piece is thoroughly inspected before being placed into its hat box and shipped.