Conner Hats has made mens cowboy hats the same way since 1969: by hand, in small batches, shaped one at a time to outlast the trend cycle. Our cowboy hats for men come in responsibly sourced Australian wool felt, breathable natural straw, and full-grain cowhide leather — a hat for the ranch, the arena, and the night out, in sizes from small to XXXL.
Start with the conditions and the look you want. Australian wool is a practical choice for shapeable Western silhouettes such as the Dakota, Outlaw, Stagecoach, and American Cattleman; the Arizona is a black wool gambler, while the Carson City offers a bowler profile. For warmer-weather wear, compare the breathable Gunsmoke Toyo, Country Western Raffia, or Hat Bar Rancher. Leather options such as the High Sierra, Down Under, Lone Wolf, and Buffalo Nickel suit shoppers who prefer a substantial outback look. Check each product’s sizing options before ordering: the collection includes numeric sizes from 6 7/8 to 7 3/4, as well as Small, Medium, Large, X-Large, XX-Large, and selected adjustable or one-size designs. For care, follow the individual product guidance before cleaning, reshaping, or treating the hat.
Material decides where a hat earns its keep.
Wool felt is the year-round workhorse. Conner's felt is Australian wool, responsibly sourced and non-mulesed — matted and compressed into a structured, water-resistant shell that keeps insulating even when damp, because wool fibre absorbs moisture into its structure rather than onto the surface (Woolmark Company research). It's the pick for cold weather and dressier western looks, and most styles crush down for travel and spring back into shape. Browse felt cowboy hats.
Straw is built for heat. Conner weaves organic raffia — a tough, biodegradable palm fiber — alongside toyo (light, packable rice-paper straw) and paper straw. The open weave moves air, which is the difference between enjoying a long day outside and cutting it short. Browse straw hats.
Leather — full-grain cowhide — is the rugged one, made for real outdoor wear and only looking better as it ages. Browse leather cowboy hats.
Across all three, Conner also works in organic hemp, organic cotton, and recycled plastic bottles, so choosing sustainably never costs you durability.
These keep the classic Western silhouette — a shaped crown and a curved, upturned brim — in cattleman and traditional shapes, with brims from about 2 to 4 inches. Because every hat is hand-shaped, you can steam and reshape the brim to sit exactly how you want it. They're made for the men who actually wear the look: riders, ranchers, and anyone heading to a country music festival or out on a Friday night. (Prefer a flat brim and telescope crown? That's gambler and outback territory, kept separate from the cowboy shape.)
Start with fit — because men hit a specific problem here. The average man's head measures about 23.25 inches (a size 7⅜), and mass-market "one-size-fits-most" hats top out near 23 inches, so plenty of guys end up in a hat that perches too high and pinches the temples. Conner sizes from S to XXXL, with 45 cowboy and outback styles running up to 25.6 inches (XXXL), deeper crowns, and drawstrings or sizing foam to fine-tune the fit. See big-sized hats.
To find your size, wrap a soft tape around your head about half an inch above your ears and brow, measure twice, and if you land between sizes, go up — foam can shim a loose hat, but nothing saves one that's too tight.
Then match material to use: straw for summer heat and long sun exposure, wool felt for cold, wet, and dress occasions, leather for hard outdoor wear. Every hat is traced farm-to-factory and shipped in biodegradable packaging instead of single-use plastic, and backed by a limited lifetime guarantee against manufacturing defects. The guarantee also includes a 50% off code to replace the same hat if yours is ever lost or stolen.
The average man's head is about 23.25 inches (size 7⅜), but sizes vary widely, so measure rather than guess. Wrap a soft tape about half an inch above your ears and eyebrows, measure twice, and match it to the size chart. If you're between sizes, go up. Conner carries S through XXXL (up to 25.6").
It should sit level, about half an inch to an inch above your eyebrows and ears, with a light, even grip. A good fit stays put when you tilt your head but never pinches or leaves a red mark. Too loose and it wobbles or blows off; too tight and it gives you a headache.
It comes down to season and use. Straw is the warm-weather choice: breathable and lightweight for long days in the sun. Wool felt suits cold, wet, and dressier occasions — it's water-resistant and holds warmth even when damp. Full-grain leather is best for rugged outdoor wear.
Yes. Standard hats stop around 23 inches, which leaves many men out. Conner offers 45 styles in XXL and XXXL — up to 25.6 inches (65cm) — built with deeper crowns, wider circumferences, and adjustable drawstrings or sizing foam so a large head gets a proper, comfortable fit rather than a squeeze.
Choose a traditional cowboy profile such as the Dakota Western Shapeable Wool, Outlaw Western Shapeable Cowboy, Stagecoach Australian Wool, American Cowboy, or American Cattleman. If you prefer a related but distinct silhouette, the Arizona is a gambler, the Hat Bar is a rancher, and the Carson City is a bowler.
Care depends on the material and finish. Use the product-specific guidance before cleaning, reshaping, or applying any treatment. In particular, do not assume that instructions for an Australian wool hat also apply to raffia, Toyo, or full-grain leather. The Quincy is identified as water resistant, but that feature should not be generalized to the collection.
Conner Hats offers free US shipping on orders over $79 and charges $7.99 for orders at or under $79. Returns are accepted within 30 days. These terms apply alongside the product coverage: a limited lifetime guarantee covering defects in materials and workmanship. The guarantee also includes a 50% off code to replace the same hat if yours is ever lost or stolen.
