A History & Brief

Factory Tour Of

SHADY BRADY Hats

 

A BRIEF HISTORY OF SHADY BRADY

While hats have changed their look, feel, style and construction material they have been around a long time. Here we explore the history of this fascinating part of fashion history and also look at the methods the Shady Brady Hat Company uses to make their hats.

John Brady has been making hats for over twenty years. His business, Shady Brady Hats is now located in Northern California. However, John's personal hat history has taken him around the world learning, developing and creating the methods used today to create the distinctive Shady Brady Hat line.

Hats have been around for a very long time. It is impossible to say when the first animal skin was pulled over a head as protection against the elements and although this was not a hat in the true sense, it was realized that covering your head could sometimes be an advantage.

One of the first hats to be depicted was found in a tomb painting at Thebes and shows a man wearing a coolie-style straw hat. Other early hats include the Pileus, which was a simple skull cap, the Phrygian cap, which became identified later as the 'liberty cap' given to slaves in Greece and Rome when they were made free men, and the Pestasos which comes from ancient Greece and is the first known hat with a brim.

Although women from an early stage were always expected to have their heads covered by veils, kerchiefs, hoods, caps and wimples, it was not until the end of the 16th century that women's structured hats, based on those of male courtiers began to be seen.

It was in the late seventeenth century that women's headgear began to emerge in its own right and not be influenced by men's hat fashions. The word 'milliner', A maker of women's hats, was first recorded in 1529 when the term referred to the products for which Milan and the northern Italian regions were well known, i.e. ribbons, gloves and straws. The haberdashers who imported these highly popular straws were called 'Millaners' from which the word was eventually derived. By the mid 1800's Swiss and Italian straws, together with imitation straws made from paper, cardboard, grass and horsehair were available to women, along with the introduction of velvet and tulle.

During the first half of the nineteenth century the bonnet dominated women's fashion, becoming very large with many ribbons, flowers, feathers and gauze trims giving an appearance of even greater size. By the end of the century, although bonnets were still prevalent, many other styles were to be found, including wide brims with flat crowns, the flower pot and the toque - feathers and veils abounded.

Although early in the 1900's most hats were enormous and adorned with flowers, feathers, ribbons and tulle, by the mid 1920's women's hair had become much shorter with the shingle cut and the cloche, which hugged the head like a helmet with a very small brim, had come into fashion. Now, after World War 1, there was suddenly such a proliferation of styles and materials that many women had to rely on the advice of milliners.

From the 1930's to the 1950's it could be said that New York, with its many European immigrants had become the world's leading millinery city, with department stores such as Sacs Fifth Avenue, Henri Bendel and Bergdorf Goodman leading the way with their own millinery workrooms.
During the 1930's and 40's the tendency was for hats to have higher crowns with smaller brims and once it was Wartime again, it was mainly the trims which were changed with women making do with turbans made from prewar materials.

By the 1950's the arrival of ready-to-wear clothes was robbing the milliners of their crucial part in the world of fashion. Equally during the War many women, who had not previously worked, found themselves employed and were then loathed to lose their newfound freedom and independence. This new situation meant, however, that they no longer had so much time or energy to spend on being fashionable.

In the 1960's the hat was once again overtaken by wigs and hairdressers, who colored, back-combed and sprayed women's hair into exotic 'sculptures'. Both men and women also realized that they could dress less formally and the hat was inevitably a temporary casualty. However, in the 1980's and 90's there has been a revival of interest in women's millinery. This was instigated, to a large extent, by public figures such as the late Princess of Wales's enthusiasm for wearing hats. Many new hat designers have emerged because of this, and therefore has made the 90's a very innovative and diverse period for hats.

Since their invention, hats have come and gone as status symbols, uniforms and fashion statements as well as being functional sports and protective headgear.

There are still, and presumably always will be, two basic styles - brimmed and brimless - and two basic forms - caps and hats. Milliners take these shapes and with the aid of many trims and details, create a never-ending range of hats for men and women.

At Shady Brady Hats we have spent years designing the process now used to make our hand crafted hats. We start with only the finest materials. In this manner we are able to guarantee our hats for a full year. Something not often found in our industry.

A FACTORY TOUR
In the early 1900's, the early days of mechanical hat making, sand bags and water were used to shape the hats and wood molds to block hats. When aluminum was available in the 30s or 40s, and also because aluminum distributes heat so well, the use of aluminum in molds changed the hat industry. Shady Brady now uses two types of presses. One, a device known as a Stomper, and a Hydraulic Press The Stomper which runs at a temperature of about 330 degrees heats the straw hat mold and you use your foot and stomp down, summoning the steam which shapes the hats within seconds/minutes depending on the type of straw being used.
 
The hydraulic press runs at about 200 degrees F. To operate the press, you utilize the presses male and female parts in harmony with the water pressure to create pressure and heat. When the press is hot and the bodies of the hats are damp you put the saddle in, line it up, you close the press and allow the pressure and heat of the machine to mold the straw hat.
 
At this point we either leave the hats a natural color. Later, dye them brown or other colors later. Many of the hats are of a similar shape and often the same blank will be used for a number of models. The blanks come in bails and usually about 300 in a bail. We buy enough for thousands at a time. One of the first steps after the initial pressing process is to sew the very edge of the brim.
 

The majority of out hats are made of Raffia. Raffia is one of our favorite straws because of it's durability and life long flexibility. It will not crack, split or break. We guarantee our hats for a year and if we can guarantee it for a year, it's going to last a whole lot longer.
 
One of the first steps in the sewing process is to sew the very edge of the brim to give the hat a very fine crease. This is the size seaming process.
 
Next we sew a galvanized steel wire into the brim to help retain it's custom shape. Then it's dried and dipped into a solution which makes the hat both hard and it's also water proofs the hat. This does not mean its going to keep a head dry. Shady Brady hats can stand up to rain just fine, but you really don't want to wear a straw hat for rain protection, unless you have a plastic sleeve for it. A good felt on the other hand, it's okay to get caught in the rain with.
 
After water proofing and the hat is dry, we re-block it, hand-shaping it into it's shape. Then after its all done and it looks like it's going to keep, that's when we put the sweat band in it. The sweat band is made out of Taffeta. Taffeta is a man made fiber that passes sweat real well, so it's not like your wearing a plastic bag on your head.
 
Finally it goes to the labeling and banding department. Here we place items on the hat such as the stampede strap, conchas, piping and leather fringes.
 
If there is any problem with a hat that has been sold the first thing Shady Brady does is, ask for the hat to be sent back to the factory. We want to see it, and John Brady personally dissects it. Then we can correct anything we did wrong. We also place on every hat a "How to keep your hat good" card along with warranty information, care and feeding, like how to reshape your hat if you wanted to and so on.
 

CLICK HERE to return to Shady Brady page.

CLICK HERE To Learn more about sizing and care of SHADY BRADY hats.

CLICK HERE to see a see an interesting article about John Brady.

 

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