Handmade black cowboy hats crafted from sustainable materials including wool, leather, and organic raffia. Each hat is designed by our family-owned business in Byron Bay and features a lifetime warranty against defects. Prices range from $80-$149 with free shipping on orders over $79.
Conner Hats' black cowboy hat collection features handcrafted styles made from Australian wool, leather, and organic materials. Each hat is designed by Will Conner, who learned traditional hat-making techniques in his father Bill's Byron Bay factory, where BC Hats created Australia's first leather hat with a shapeable brim in 1969.
All hats include shapeable brims (3.5-4 inch width for sun protection), adjustable sweatbands, and are backed by our lifetime warranty against manufacturing defects.
Black cowboy hats work for both formal and casual occasions:
The cowboy hat market has grown 4.2% annually since 2023, with social interest increasing 400% year-over-year driven by Western fashion trends and country music influence.
Most hats ship within 1-2 business days with free shipping on orders over $79.
Black cowboy hats are typically made from wool felt, fur felt (beaver or rabbit), leather, or straw. Conner Hats uses Australian wool felt ($95-$100), full-grain leather ($95), and organic materials like hemp and raffia. Wool felt hats offer water resistance and durability, leather provides natural weather protection, and straw options are lightweight for summer. Higher-quality felt hats (10X, 20X ratings) contain more fur content and cost $200-$2,000 from premium brands, while our wool felt hats deliver quality craftsmanship at $95-$149.
No. Black cowboy hats work for both formal and casual wear. Felt hats in darker tones like black are traditional for formal Western events (weddings, dances, evening gatherings), but they're equally suitable for everyday ranch work, outdoor activities, and casual outings. The versatility comes from the material—felt provides warmth and structure for formal settings, while leather and straw versions offer rugged durability for work and recreation.
Measure your head circumference where the hat will sit (about 1/4 inch above your ears). Use a cloth measuring tape and match the measurement to our size chart. Cowboy hats should fit snug initially—they'll loosen and conform to your head shape with wear as they warm from body heat. If between sizes, size up; a slightly larger hat can be adjusted with padding, while a too-small hat causes discomfort. Our hats come in sizes Small (6 7/8 - 7), Medium (7 1/8 - 7 1/4), Large (7 3/8 - 7 1/2), and X-Large (7 5/8 - 7 3/4).
Yes, with proper material choice. Wool felt and leather cowboy hats are naturally water-resistant and handle light to moderate rain well. Let them air dry away from heat sources—high heat causes warping and expansion. Straw hats can get wet but should also air dry completely. Avoid prolonged soaking with any material. Our wool felt hats are treated for water resistance, and leather hats develop a natural patina with weather exposure.
Cowboy hats typically feature a taller crown (4.5-5 inches) with a cattleman or pinch-front crease, and a wider brim (3.5-4 inches brim width for sun protection) with more pronounced upward curl. Outback hats have a lower, rounded crown and a flatter brim, often with ventilation eyelets. Both styles appear in our black collection—cowboy styles work for Western events and rodeos, while outback styles suit hiking, travel, and outdoor work. The choice depends on your face shape and intended use.
Brush your hat regularly with a soft-bristle hat brush to remove dust and dirt. Always store it upside down on its crown (never resting on the brim, which causes warping) in a cool, dry place. For stains, use a damp cloth with mild soap on wool felt. Professional cleaning and reshaping every 1-2 years extends the hat's lifespan. Our wool felt hats are crushable for travel—they'll bounce back to shape. Avoid leaving hats in hot cars or direct sunlight for extended periods.
Every Conner Hat is warranted to the original owner against defects in materials and workmanship for the lifetime of the hat. If a hat fails due to a manufacturing defect or faulty materials, we'll replace it. Normal wear and tear, damage from misuse, or improper care aren't covered. We also offer free 30-day exchanges through our REDO program (USA only) if sizing or style doesn't work out.
We're a family-owned business that controls our entire production process, from design to distribution. Will Conner designs every hat and learned traditional techniques from his father Bill, who founded BC Hats in 1969. By manufacturing sustainably and selling directly to customers, we eliminate markup layers that add $50-$200 to competitor pricing. Wool felt hats range from $50-$2,000 depending on quality, with our collection positioned at $95-$149. You're paying for craftsmanship, not brand premium.
Yes. We use organic cotton, hemp, cruelty-free Australian wool, and recycled materials across our collection. Our warehouse operates on solar power, we use biodegradable string instead of plastic tag connectors, and hats ship on flat cardboard instead of plastic bags. We've committed to reducing single-use plastic since our founding, including a full line of hats made from recycled plastic bottles. Our wool is sourced from cruelty-free suppliers, and leather comes from sustainable tanneries.
For summer, choose straw or lightweight wool options. Our Country Western Raffia Shapeable Hat ($80) is hand-braided from organic raffia and offers breathability with a shapeable brim. The Gunsmoke Western Toyo Hat ($80) uses paper straw with a tight weave for durability and ventilation. If you prefer felt for formal summer events, look for lighter-weight wool felt with ventilation eyelets. Straw hats are traditionally worn from spring through early fall, while felt hats are reserved for cooler months, though modern style allows flexibility based on climate and occasion.
