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    New Arrivals: Handmade Hats with a Limited Lifetime Guarantee

    Explore our latest handmade hat styles crafted from sustainable materials including organic cotton, hemp, non-mulesed wool, and natural raffia. Family-owned, each hat is backed by a limited lifetime guarantee against defects — quality craftsmanship without luxury brand pricing.

    Meet the newest handmade hats from Conner Hats, designed for shoppers looking for practical sun coverage, western character, everyday casual wear, or an easy warm-weather accessory. This 33-style collection includes straw cowboy and western hats, wool cowboy and outback styles, raffia ranchers, Toyo straw fedoras, baseball caps, and women's boho hats. Materials include organic cotton, hemp, non-mulesed Australian wool, natural raffia, straw, and oilskin or waxed cotton across selected designs. Choose from options such as the Silver Dollar Saloon, Hat Bar Rancher, Avalon Toyo Straw Fedora, Koala Lover Cap, or Uluru Outback Wool Hat. Sizes range from 6 7/8 through 7 3/4, plus Small to X-Large, adjustable, and one-size options.

    Crafted For Everyday Wear

    • Handmade construction: These hats are made for shoppers who value individual style and practical materials.
    • Material variety: Choose organic cotton, hemp, non-mulesed Australian wool, natural raffia, straw, or oilskin and waxed cotton options.
    • Useful range: The collection covers baseball caps, fedoras, wide-brim western hats, outback styles, and boho designs.
    • Flexible fit: Available sizing spans hat sizes 6 7/8 through 7 3/4, along with Small through X-Large, adjustable, and one-size choices.
    • Family heritage: Bill Conner learned leatherwork in St. Augustine in 1969, later made hats in Byron Bay for over 50 years, and his son Will created the brand.
    Conner Hats Small / Ivory Silver Dollar Saloon Straw Cowboy hat
    Conner Hats Small / Ivory Walk The Line Straw Cowboy Hat
    Conner Hats Small / Ivory Walk The Line Straw Cowboy Hat

    Find Your Best Hat

    Start with the setting and silhouette. For western character, compare the straw Silver Dollar Saloon, Tennessee Whisky, and Walk The Line with wool options such as the Hat Bar Rancher or American Cattleman. For a lighter, natural look, consider the Avalon Toyo Straw Fedora, Aspen Vented Toyo Straw Hat, or a raffia style such as the Billings or Bozeman. The Koala Lover Cap offers a familiar baseball-cap shape, while the Tambourine and Uluru suit an outback-inspired look. Check the individual product listing for its material, shape, and available sizes. Measure your head and match the result to that listing’s size guidance; adjustable and one-size options can offer additional flexibility. Care should follow the instructions for the specific material and product, since straw, wool, raffia, cotton, and oilskin or waxed cotton should not automatically be treated alike.

    Centered Table
    Material Best For Temperature Range Key Benefit
    Raffia Straw Summer, beach, golf 70°F+ Lightweight, breathable
    Wool Year-round, western style All seasons Water-resistant, durable
    Felt Cool weather, dress Below 70°F Structure, insulation
    Hemp Outdoor activities 65°F+ UV-resistant, sustainable
    Leather Rugged outdoor use All seasons Durability, shapeable

    Frequently Asked Questions

    Our new arrivals include recently released styles and seasonal additions to our handmade hat collection. Current new styles include the Renegade Australian Wool Hat, Cowboy Country Straw Hat, American Cowboy Hat, and several raffia cowboy styles. We add new designs throughout the year based on seasonal needs, customer feedback, and innovations in sustainable materials. Each hat is handmade with the same quality standards we've maintained since founder Will Conner established the brand, following 50 years of hatmaking tradition started by his father Bill Conner in Byron Bay, Australia in 1969.

    Our new arrivals feature organic cotton, hemp, responsibly sourced Australian wool, organic raffia, recycled polyester made from plastic bottles, and natural materials like leather and paper straw. Organic cotton reduces water pollution by 5x compared to conventional cotton and eliminates synthetic pesticides. Hemp requires 1.46 global hectares vs. 2.17 for organic cotton—33% less land and is naturally UV-resistant. Our non-mulesed wool comes from ethically raised sheep, and we use recycled PET fabric to keep plastic bottles out of waterways. All materials are selected to minimize environmental impact while delivering durability and comfort.

    Pricing varies by material and style, and the current price is shown on each product page. Every Conner hat is handmade, carries a limited lifetime guarantee against manufacturing defects, and US orders over $79 ship free.

    Most Conner hats offer UPF 50+ protection, blocking 98% of harmful UVA and UVB rays. Wide-brim styles (3+ inches) provide the best coverage, protecting your face, neck, ears, and upper back—areas most vulnerable to sun damage. Research from Stanford University shows that individuals who frequently wear protective clothing like hats have 27% lower odds of multiple sunburns compared to sunscreen users alone. Materials like hemp, organic cotton, and tightly woven straw offer natural UV resistance, making our hats ideal for outdoor activities where sun exposure is a concern.

    Yes. Each Conner Hat is crafted with handmade care in small-batch production, ensuring quality and attention to detail. Our founder Will Conner learned hatmaking in his father Bill's Byron Bay factory, where BC Hats created Australia's first leather hat with a shapeable brim in 1969. We source from suppliers who pay fair wages and practice ethical treatment of employees. Handmade construction means each hat receives individual attention during cutting, shaping, stitching, and finishing—resulting in better fit, durability, and craftsmanship than mass-produced alternatives.

    Conner Hats are warranted to the original owner against manufacturing defects. If your hat fails due to a manufacturing defect or faulty materials, we will replace it. This warranty reflects our confidence in our handmade quality and sustainable materials. Normal wear and tear, damage from misuse, or alterations are not covered, but we stand behind the craftsmanship and durability of every hat we make.

    Choose straw (like raffia) for temperatures above 70°F—they're lightweight, breathable, and allow airflow, making them ideal for summer, beach, golf, and gardening. Choose felt or wool for cooler weather and year-round wear—they're water-resistant, provide insulation, and maintain shape in varied conditions. Leather works for both warm and cool weather but runs warmer in summer heat. Consider your primary use: if you need sun protection for outdoor activities, wide-brim straw or hemp styles offer maximum coverage and ventilation. For western style or durability in rugged conditions, wool and felt provide structure and weather resistance.

    Most styles are available in Small (21 1/4-21 5/8 inches / 54-55 cm), Medium (22-22 3/8 inches / 56-57 cm), Large (22 3/4-23 1/4 inches / 58-59 cm), X-Large (23 1/2-24 inches / 60-61 cm), XX-Large (24 3/8-24 3/4 inches / 62-63 cm), and XXX-Large (25 1/8 inches / 64 cm). Some styles offer S/M, L/XL, or adjustable sizing with drawstrings or elastic bands. To measure your head, place a flexible tape measure around your head a quarter of an inch above the ear, across the forehead. Buy a hat that fits snug around the head—hats expand with heat from your head and will loosen to conform to your shape. If you're between sizes, size down for styles with adjustable features, size up for fixed sizing.

    Begin with the cowboy and western styles in the collection. Straw options include the Silver Dollar Saloon, Tennessee Whisky, Walk The Line, Cowboy Country, and Cheyenne Roper. For a wool alternative, compare the Hat Bar Rancher, Austin Cattleman, American Cattleman, or Stagecoach Australian Wool Cowboy Hat.

    Use the care guidance supplied with the specific product, because this collection combines straw, raffia, wool, cotton, and oilskin or waxed cotton. Avoid assuming that one cleaning or storage method works for every material. If you are unsure, check the listing or contact Conner Hats before cleaning or treating the hat.