Our Australian Made collection features hats handcrafted in Byron Bay, Australia by Bill Conner (BC Hats), who created Australia's original leather hat with a shapeable brim . These aren't mass-produced replicas—they're the original designs that defined the category, made by Bill Conner using the techniques that earned him the 1993 Small Business Exporter of the Year Award from the NSW government.
Authentic construction heritage: Bill Conner's construction method helped create Australia's original leather hat with a shapeable brim with BC Hats in Byron Bay. His technique for incorporating iron wire into the hat brim allows the brim to be shaped and hold its form, creating the signature look and functionality that Australian stockmen, ranchers, and outdoor workers have relied on for over 50 years.
Premium materials: Our Byron Bay-made hats use genuine oily Australian leather (water-resistant steer hide) and canvas with mesh ventilation. The natural oil treatment in premium Australian leather creates a water-resistant barrier while allowing the leather to breathe, providing protection and comfort in all conditions.
Crushable travel design: Reinforced with coiled spring wire, these hats can be crushed flat and packed anywhere, then pop back to perfect shape. This crushable construction makes them ideal travel companions for adventurers who need authentic protection without sacrificing pack space.
Limited availability: Bill Conner has retired, making current inventory the last BC Hats available worldwide—now collector's items. These represent the final opportunity to own an original Australian-made hat from the craftsman who invented the category.
| Feature | BC Hats (Australian Made) | Mass-Produced Outback-Style |
|---|---|---|
| Manufacturing location | Handcrafted in Byron Bay, Australia | Typically manufactured overseas |
| Materials | Genuine Australian oily leather or canvas | Often synthetic or imported materials |
| Brim construction | Wire-reinforced shapeable brim with memory | Standard brim without wire reinforcement |
| Crushable design | Coiled spring wire allows crushing and shape recovery | Not crushable or loses shape when compressed |
| Heritage | Original designs by Bill Conner, who created Australia's original leather hat with a shapeable brim | Replicas of Australian outback style |
| Durability | Customer reports of 30+ years use | Typically 2–5 years |
| Availability | Limited (Bill Conner retired, final inventory) | Widely available |
Currently available Australian-made styles:
In April 1969, Bill Conner learned the art of handmade leatherworks in St. Augustine, Florida. The 1982 film The Man from Snowy River popularized BC's iconic hat style, allowing Bill to hire his first employees and start a small factory. When Crocodile Dundee was released in 1986, Bill's stockman hat became a bestseller, and in 1988, BC Hats became the official hat of the World Expo held in Brisbane.
For over 50 years, Bill Conner refined his craft in Byron Bay, creating hats that balanced traditional Australian outback functionality with modern durability. His son Will Conner now carries forward the family legacy through the Conner Hats brand, distributing the final BC Hats inventory alongside his own sustainable designs.
Australian Made outback hats suit anyone who values authentic craftsmanship and proven durability:
BC Hats in our collection were made in Byron Bay before 2020, when Bill Conner’s workshop was still operating. They reflect his pioneering design for Australia’s original leather hat with a shapeable brim. BC crushable styles and Cool as a Breeze use coiled spring wire to let you shape the brim while helping it retain its form. These distinctive construction details set them apart from other outback-style hats.
Bill Conner retired in 2020, ending production of BC Hats after 50 years of manufacturing in Byron Bay. Current inventory represents the last BC Hats available worldwide. His son Will Conner continues the family hat-making tradition through the Conner Hats brand, which includes both the remaining BC Hats inventory and new designs made with sustainable materials.
BC Hats crushable construction includes coiled spring wire reinforcement, allowing the hats to be compressed flat for packing in luggage or backpacks, then spring back to their original shape when removed. This feature makes Australian Made outback hats practical for travel while maintaining the structured look and shade of a traditional outback hat. The crushable design doesn't compromise durability—customers tell us their BC Hats have lasted 30+ years.
Australian oily leather hats are naturally water-resistant due to the oil treatment in the leather. For cleaning, wipe with a damp cloth and allow to air dry away from direct heat. The leather will develop a patina over time that adds character. If the hat loses its shape, use steam from a kettle to soften the material, then reshape by hand and allow to cool. The wire-reinforced brim can be shaped to your preference and will hold that shape. Store flat or hanging by the crown (not the brim) to maintain structure.
The Bac Pac Traveller uses water-resistant oily Australian leather with a leather inner sweatband, offering water resistance and the classic Australian leather outback look. The Cool as a Breeze uses canvas construction with a mesh crown for enhanced breathability in hot conditions, while maintaining the Australian outback silhouette. Both are crushable and feature removable hatbands. Choose leather for durability and weather resistance; choose canvas mesh for ventilation in high-heat environments.
BC Hats are available in standard hat sizes from Small through XX-Large. To determine your size, measure the circumference of your head about 1/2 inch above your ears using a flexible tape measure. Compare your measurement with these ranges: Small, hat size 6 3/4-6 7/8, fits 21 1/4-21 5/8 inches (54-55 cm); Medium, 7-7 1/8, fits 22-22 3/8 inches (56-57 cm); Large, 7 1/4-7 3/8, fits 22 3/4-23 1/4 inches (58-59 cm); X-Large, 7 1/2-7 5/8, fits 23 1/2-24 inches (60-61 cm); and XX-Large, 7 3/4-7 7/8, fits 24 3/8-24 3/4 inches (62-63 cm). A 22-inch head is a Medium (hat size 7). Australian outback hats should fit snugly without being tight. The leather inner sweatband will conform to your head shape over time for a custom fit.
The price reflects handmade construction in Byron Bay and the materials used, as well as the limited availability of original BC Hats. These hats were made before Bill Conner retired and closed his workshop in 2020, so they are no longer being produced. Depending on the style, BC Hats use genuine Australian oily leather or canvas. BC crushable styles and Cool as a Breeze have coiled spring wire to help the brim hold its shape. With only limited stock remaining, they differ from mass-produced, similar-looking hats.
