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DIY hat block using expanding foam #2 (and blocking straw)

This is part 2 of experimenting with polyurethane foam (PU foam/expanding foam) to make a DIY hat block. Whilst I would always recommend buying a wooden hat block directly from a hat block maker, not everyone has the money to afford this when just starting out. There’s also a little bit about blocking straw.

#millinery #hats #hatblock

Watch part 1 here: https://youtu.be/GreX46wMV5w

Tools & Materials 1

  • Small tub of water
  • Wood filler
  • Selection of spatulas for the wood filler (I’m using some old plastic cards)
  • Face mask (because of the sanding)
  • Sanding block
  • P80 sand paper
  • Old rag cloth
  • Measuring tape
  • Pencil and or sharpie marker
  • Clingfilm

Tools & Materials 2

  • Headsize collar (I don’t have one, so I’m using a crown block)
  • Clingfilm
  • Masking tape
  • Straw brim for blocking
  • Blocking string
  • Blocking pins
  • Large rubber band
  • Thimbles
  • Steamer
  • Non-toxic straw stiffener (I’m using Poly Vinyl Acetate (PVA) diluted 1 to 4 with water)
  • Paint brush
  • Hair dryer (if you are impatient like me)
  • Baking paper
  • Iron

Suggested Suppliers

  • Your local hardware or DIY shop.

UK Wooden Hat Block Makers