Crafted in the Northwest. Tailored for You.
Custom hats, meticulously shaped by hand for those seeking a distinct, elevated style. Tailored for a perfect fit the very first time—crafted with absolute dedication, zero shortcuts, and no fuss.
Mahoney
In 2021, I was hit head-on while riding my Harley. By every law of physics and medicine, I shouldn’t have survived that crash. But I did. While my body recovered, my mind was stuck processing the heavy weight of survival guilt. I felt completely different inside, and I needed a way to express this new version of myself to the outside world.
Looking for a way to ground myself, I sought out a custom hat maker. I wanted a custom felt hat with a leather band etched with symbols that told the story of my accident and my survival. But when the hat finally arrived, it didn’t fit. I was incredibly frustrated, but the maker promised to fix it. Instead, he ghosted me. He took my money and disappeared.
After sitting with that frustration for a while, I decided to channel it into purpose: If no one else was going to make this hat right, I would learn how to make it myself.
I didn't just guess my way through it, either. I sought out the best and learned the craft directly from a third-generation family of master hat makers. I mastered the traditional techniques, the patience, and the precision required to shape raw quality material into something meaningful. Learning to create that first piece gave me my voice back. It gave me my confidence back, and it gave me a brand-new mission.
Now, I build hats for you. Because of my own experience, I refuse to let a customer down. My goal is to craft a premium, custom piece of handmade armor that is built to fit you perfectly the very first time. Whether you are celebrating a milestone, marking a comeback, or just claiming who you are, I shape every single hat by hand to help you carry yourself with that same unbreakable pride.
— Mahoney
Custom, One Hat at a Time
No product wall to scroll. Every hat is built with you, for you — start to finish.
The Custom Hat
A hat made to order and shaped by hand — your style, your crown and brim, your call. Built one-on-one so it's genuinely yours, not pulled off a shelf.
Dialed-In Fit
A hat that measures right but doesn't fit right is a waste of money. I take the time to get your shape and fit dead-on, so it sits the way it should the first time you put it on.
Clean, Understated Detailing
Hand-finished leatherwork, clean angles and stamped detail — understated and built to last. Nothing fussy, nothing overworked. Just a sharp hat that carries itself.
How It Works
Four steps from "I want a real hat" to wearing it.
Reach Out
Send an inquiry and tell me the hat you've got in mind.
Get Fitted
We nail down your measurements, shape, and the details that make it yours.
Shaped by Hand
I block, shape, and finish your hat — no shortcuts, built to last.
Wear It
A one-of-a-kind hat that's yours, made to fit and made to go the distance.
Hats by Mahoney
A look at the hats coming off the bench.
Book a Custom Hat
Fill out the form and I'll be in touch to talk through your hat — the style, the fit, and how we get it built. One-on-one, by appointment.