Baseball Cap

LEATHER
SIZE
¥29,700
/
Tax included.

A simple six-panel baseball cap with an adjustable back strap.

At first glance, the design may look like a straightforward, classic baseball cap. However, reaching this final shape took a considerable amount of time and work.

Leather behaves very differently from woven fabric, and using the same patterns as a conventional fabric cap simply did not produce a shape we were satisfied with. We made a sample, redrew the patterns, made another sample, adjusted them again, and repeated the process over and over.

I don’t remember the exact number, but we made at least ten prototypes before arriving at the final shape.

With a hat, even a difference of just a few millimeters can completely change its appearance and fit.

Finding the right balance is one of the most difficult parts of hatmaking, and also one of the details I care about most.

The simpler the design, the more important the silhouette and fit become.

The stitching on the crown is sewn one row at a time using a single-needle sewing machine.

Double-needle machines, commonly used in mass-produced hats, can sew two parallel rows of stitching at once, but typically leave a spacing of around 10 mm between them.

This works well with woven fabrics, but on leather, that width can make the stitching look too heavy.

By sewing each row individually with a single needle, we are able to reduce the spacing to approximately 4 mm, giving the cap a cleaner, sharper appearance. Whether in hats or clothing, the narrower the spacing between parallel rows of stitching, the more noticeable even the slightest deviation becomes, requiring a high degree of precision.

Although the cap has an adjustable back strap, we chose not to make it one-size-fits-all.

Instead, it is available in four sizes.

Most mass-produced baseball caps are made in a single size and rely on the adjuster to accommodate different head sizes. When a cap has to be tightened or loosened too far, its intended silhouette can easily become distorted.

We also took a different approach to grading the patterns between sizes.

In mass production, it is common to adjust the size by changing only the center panels of the six-panel crown while keeping the other panels unchanged.

While efficient, this method can compromise the overall proportions. The master size may be perfectly balanced, but as only the center panels change in the other sizes, the balance of the entire crown can shift. Another issue is that the crown depth does not necessarily increase as the size becomes larger.

For this cap, all six crown panels are individually redrawn for each size.

This allows the cap to maintain its intended silhouette and proportions throughout the size range, while the crown depth changes naturally in relation to each size.

It may look simple, but its shape is the result of countless small details and refinements.

COW HIDE

1.2 mm full vegetable-tanned cowhide, carefully conditioned with oil for a supple feel and just the right amount of firmness. With continued wear, the leather gradually conforms to the wearer and develops a deeper, richer luster.

HORSE HIDE

1.2 mm full vegetable-tanned brown-core horsehide with a naturally firm, structured feel. As the surface wears over time, subtle hints of the brown base begin to emerge, creating greater depth and a distinctive aged character.

DEERSKIN SUEDE

Soft, substantial deerskin suede with a smooth hand and refined matte finish. Naturally supple and comfortable, the surface develops greater depth and character with continued use.

NUBUCK

Oil-treated nubuck made from cowhide, with a generously oiled finish that gives the leather an exceptionally soft, supple feel. With continued use, the surface develops greater depth, richness, and individual character.

SHEEPSKIN

Tannin-tanned brown-core sheepskin with an exceptionally soft, lightweight feel. Over time, the underlying color gradually begins to emerge, creating a subtle, understated patina unique to the leather.

GOATSKIN

Tannin-tanned brown-core goatskin that combines a lightweight, supple feel with excellent durability. As it ages, the underlying color gradually begins to show through, while the surface develops a subtle luster and greater depth of character.

Please note that sizing may vary slightly depending on the type and thickness of the leather.

To preserve the natural character of the leather, we do not apply treatments intended to conceal variations in color, marks, scars, or other natural characteristics. As a result, the leather may show subtle stains, scratches, wrinkles, grain variations, and other irregularities. The appearance may also vary between individual panels depending on the section of the hide from which they are cut. These are natural characteristics of genuine leather and are not considered defects.

The base of the crown is reinforced to help prevent stretching and maintain the intended fit.

Every effort is made to photograph our products as accurately as possible. However, actual colors may vary slightly depending on your device, monitor settings, and lighting conditions.

International Returns & Size Changes

We do not offer direct size exchanges for international orders.

If you would like a different size, please return the original item for a refund and place a new order for your preferred size.

To request a return, please contact us at info@brunel-hatmakers.com within 7 days of receiving your order.

Return Conditions

• Items must be unused, unworn, and in their original condition, with all tags and accessories attached or included where applicable.

• We reserve the right to refuse a return if the item shows signs of wear, damage, alteration, or use.

• Refunds are issued for the product price only. Original shipping charges are non-refundable.

• Return shipping to BRUNEL & Co. HATMAKERS is the customer’s responsibility.

• If you place a new order for a different size, all shipping costs for the new order are the customer’s responsibility.

• Any customs duties, import taxes, VAT, handling fees, or other charges incurred on the new order are the customer’s responsibility. Please note that these charges may apply again even if duties or taxes were paid on the original order.

• Availability of your preferred size cannot be guaranteed. We recommend checking availability before returning your original item.

Defective or Incorrect Items

If you receive a defective item or an item different from what you ordered, please contact us before returning it. In these cases, BRUNEL & Co. HATMAKERS will cover the necessary return and replacement shipping costs.

Please contact us at info@brunel-hatmakers.com before sending any item back.

Worldwide shipping available.
All orders are shipped from Japan via EMS (Japan Post).
Shipping fee
Flat rate: ¥4,500 worldwide.
International orders may be subject to import duties or taxes depending on the destination country. These charges are the responsibility of the customer.