Hat Making Tool: Rounding Jack Hat Brim Cutter, Walnut Deluxe Model, Clockwise Cutting

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Project by Mark A. DeCou posted 04-23-2008 01:31 AM 16991 views 0 times favorited 9 comments Add to Favorites Watch


To discuss my current inventory of hatmaking tools, email at: [email protected]

ARE LISTED IN MY ETSY.COM ONLINE SHOP, click here to check inventory


Video: What does this thing do? Watch this video by California Custom Hat Maker Tom Gomez from Premier Panama Hats using one of my Rounding Jacks on a felt body Hat. Here is a link to Tom's ebay Store

To See More Hatmaking Tool Videos from Tom Gomez:
  1. Foot Tollikers: click here to see
  2. Kettle Curling Tool: click here to see one
  3. Puller Downer: click here to see one:
  4. Pusher Downer: click here to see one


Artisan Hat Tools by Mark DeCou Studio
(Do you want to see More? Just follow these links):

ARE LISTED IN MY ETSY.COM ONLINE SHOP, click here to check inventory

Rounding Jacks, Collector’s Editions:
  1. Ebonized Walnut Clockwise with Laser Engraving
  2. Walnut Counter Clockwise w/Laser Engraving
  3. Walnut Uni-Directional Cutter
Rounding Jacks, Deluxe Model:
  1. Maple Deluxe Model, Counter Clockwise Cutter
  2. Maple Deluxe Model, Clockwise Cutter
  3. Walnut Deluxe, Counter Clockwise Cutter
  4. Walnut Deluxe, Clockwise Cutter
Rounding Jacks, Hobbyist-Hatter Model:
  1. Walnut Hobbyist-Hatter Model, Counter Clockwise Cutter
  2. Walnut Hobbyist-Hatter Model, Clockwise Cutter
Bench-Top Display Stands for Rounding Jacks:
  1. Walnut Bench-Top Display Stand
  2. Oak Bench-Top Display Stand
    Click here to check inventory
Customized Rounding Jacks, Personalized for Specific Hatters:
  1. Spradley Hats in Apline, TX
  2. Rachel Pollock of La Bricoleuse
  3. Brainpan Hat Shop in Sumner, WA
  4. Steve Delk's Adventurebilt Hat Co.
  5. Marc Kitter's Adventurebilt Hat Co.
  6. Pyrate Trading Co.
  7. Hatman Jack at Wichita Hat Works
  8. Inaaya Hat Co.
  9. Penman Hat Co.
Formillons & Conformateurs:
  1. Complete Restoration of a Maillard Conformateur and Formillon
  2. New DeCou Formillion & Conformer, Prototypes #1 & #2
  3. Custom Designed Conformateur Carrying & Storage Case
  4. New Plot Base Board for the Maillard Allie Formillon
  5. Maple Wrench for Tightening Formillon Thumbnuts
Foot Tollikers:
  1. Left-Handed & Right-Handed Foot Tolliker
  2. Foot Tolliker: Elk Antler & Birch Wood, on a Display Stand
  3. Foot Tolliker: Walnut Wood, on a Display Stand
  4. Foot Tollikers: Three in White Birch Wood
  5. Foot Tollikers: Walnut Wood Set of Four
  6. Foot Tollikers, Birch Wood Double Set, on Display Stand
Brim Edge Curling Tools:
  1. Hinge-Shackle Curling Tool for the Homburg Hat
  2. Full Circle Shackle Curling Tool
  3. Half Circle Shacking Curling Tool
  4. Groove Tolliker Curing Tool
Band Blocks:
  1. Thick Poplar Wood, Various Sizes and Oval Shapes, with Tapered Sides
Crown Blocks
  1. Long Oval Crown Block Sculpting Work
Hat Block Spinners:
  1. Late Turned Hat Block Spinners
Flange Stands:
  1. Heavy Duty Flange Stands
Puller Downers:
  1. Puller Downers
Pusher Downers:
  1. Pusher Downers
Hat Racks, Hat Stands, & Cedar Band Blocks:
  1. Hat Racks to keep oval shapes
Stainless Steel Slip Stick:
  1. “Coming Soon”, please check back.

(Note:This project story, project design, and photos are protected by copyright in 2008-2010 by the Author, M.A.DeCou., all rights reserved, no use allowed without expressed written permission.)

-- Mark DeCou - American Contemporary Craft Artisan -

9 comments so far

View Roger Strautman's profile

Roger Strautman

657 posts in 4640 days

#1 posted 04-23-2008 02:13 AM

OK Mark, you out did yourself this time! This is a very well thought thru piece both cosmetic and functional. My hats off to you. WELL DONE!!!

-- " All Things At First Appear Difficult"

View Karson's profile


35201 posts in 4907 days

#2 posted 04-23-2008 02:55 AM

Roger that’s a cheap shop. Your hats off to him.

Mark, great job. If I ever join the hobby of the month club again. I’ll look you up.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Dan'um Style's profile

Dan'um Style

14181 posts in 4489 days

#3 posted 04-23-2008 04:53 AM

great tool ! hope you found a niche. shipping should be very reasonable for the buyer.

-- keeping myself entertained ... Humor and fun lubricate the brain

View Mark A. DeCou's profile

Mark A. DeCou

2009 posts in 4912 days

#4 posted 04-23-2008 06:44 AM

Niche Dan? Don’t you think everyone would want one? I could make display stands like I do on my knives and powder horns for mantle presentation. Ha.

Thanks also Karson and Roger, you are a constant encouragement to me, I appreciate you very much


-- Mark DeCou - American Contemporary Craft Artisan -

View TomK 's profile


504 posts in 4381 days

#5 posted 04-24-2008 05:19 AM

I can see how this works well for round brims, but how about oval or elliptical brims? If it just indexes off the crown, how can you vary the brim proportions? Anyway, the construction looks great. Is there a future for a custom brassiere tool?

-- If you think healthcare is expensive now, wait until it's free! PJ O'Rourke

View Mark A. DeCou's profile

Mark A. DeCou

2009 posts in 4912 days

#6 posted 04-24-2008 03:04 PM

Good thoughts TomK. The cutting of the brim is done by following the crown around, keeping the cutter pushed against the crown. The crown is an oval of various sizes from about 6-1/2 up to 8-1/4 depending on the client’s head size and shape, and then the brim is trimmed following the oval of the crown. Since the crown is an oval, or elliptical, the cutter cuts an oval also. Some hatters like to pull the tool in a clockwise rotation, while others like to push in a counter-clockwise rotation. The cutting head will be rotated either direction for the preference of the operator. If I can get some photos of how this is actually accomplished by a hatter, I’ll go back and post them.

thanks for your question,

-- Mark DeCou - American Contemporary Craft Artisan -

View fedora's profile


2 posts in 4180 days

#7 posted 05-05-2008 07:22 PM

I own vintage rounding jacks, and I must say this one here is a piece of art. Using the readily available blade is a stroke of genius. Once I get this baby in, I will retire my vintage ones, and just look at them as antiques should be treated. Thanks for providing this to us hatters, and the price is simply unreal. These babies go for 750.00 from others, and they are no where as attractive as what you have come up with Mark! I have already told a few guys about these, so expect more orders!!! These are simply beautiful. Thanks. Fedora(hatmaker for Harrison in the new soon to be released film) Expect an order from my partner Marc, from Germany, the other half of the hatmaking team for the new Indy film.

View Bill's profile


2579 posts in 4668 days

#8 posted 05-05-2008 07:36 PM

Nice work Mark. I did not know there was so much work in making hats. You did an excellent job on these tools.

-- Bill, Turlock California,

View Mark A. DeCou's profile

Mark A. DeCou

2009 posts in 4912 days

#9 posted 05-05-2008 08:10 PM

Thanks Steve and Bill.

Steve, you having been awarded the hatwork on the Fedoras for the new Indiana Jones Film is such an honor for you. I do appreciate being loosely tied to that by getting you a Rounding Jack.

I hope the antique cutters will see the “new kid” on the block as a respite and reward for the many years of faithful service they have provided.

(P.S., I do realize that old rounding jacks are inanimate objects without thought, or personalities, but it was a fun concept to think about).

Many blessings for your business, and for the success of brim “Hats Making a Comeback” in our culture.

If you wanted to provide some photos of the way a Rounding Jack is actually used in your hat shop, I would welcome the chance to share the space with you on that, or just link your blog on how it is done. I’ve gotten quite a few emails from folks asking how it is done, and wanting more photos of the process. What you feel you can share, I’ll be glad to help how I can.


-- Mark DeCou - American Contemporary Craft Artisan -

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