Making a Hat Band

[Rockrz]

Wasn't sure which forum to put these question in....

I'm wanting to make my own hat band similar to the Donnie Van Zant hat band (see pic below), and I've already ordered some 1 1/4 inch Silver Slotted Star Conchos, and a black Buffalo Hide Leather belt that is 1 1/4 inches wide  (see attachments for pics)

All I still need is some leather that is flat black that's fits in to the slots on the conchos and some leather working tools to be able to punch a rectangular hole in the leather belt I'll be using.

I'll just run the thin leather strap thru each concho thru the holes in the belt where it will run on the back side of the belt all the way around where I'll have to figure out a way to fasten the back where the two ends come together.

Questions...

1) Where can I find a tool that is rectangular shaped once I find the exact size I'll be needing (I'll know once I measure the slots)

2) I was thinking of somehow tying the thin strap that will be routed thru as slotted concho where it all comes together in the back of the hat... so what are some ideas on how to do that?

One of the attachments to this message is a pic of the hat band I'm wanting to re-create since I cannot find anywhere that this can be purchased by itself without also buying the hat too which is pretty expensive

[fredk]

For punching the slots in the leather buy a rectangular hole punch of the appropriate size.

They are easily available

Your chosen belt size might be too narrow for the conchos

Edited March 24 by fredk

[Rockrz]

13 minutes ago, fredk said:

Your chosen belt size might be too narrow for the conchos

Yeah, I was looking at the pic of this guy's hat band and noticed it was slightly wider than the concho so I may need to revisit that part of the project.  I could use some one inch conchos rather than the 1 1 /4

I was thinking of buying a black belt that has a seam sown in on the edges hopefully with black thread.

Any recommendations for a good place online to buy tools?

Edited March 24 by Rockrz

[fredk]

51 minutes ago, Rockrz said:

Any recommendations for a good place online to buy tools?

I can't advise as I don't know where in the world you're located. This is a world-wide forum

1" conchos on a 1 1/4 will be big enuf

[Rockrz]

I'm in the US and would rather order from a vendor within the US as it's easier to do returns if need bee with US vendors verses international vendors.

[fredk]

Some of the US members will be along soon and they can best advise where to get oval punches

[Rockrz]

OK, thanks.

Just thought I'd ask since I'd imagine some vendors are better than others

[AlZilla]

Assuming you want the band permanently attached to the hat ...

How you attach the concho strap kind of depends on how it all comes together in the back. Some options are to use Chicago screws or hand sew.

Is it going to join between conchos, or under one of them? 

You could butt the ends of the band and use an X stitch or a corset stitch. You could skive the ends to a taper and overlap them.

Maybe all the parts could join at center/back between conchos, everything could butt together and use about 3 rivets on each side of the joint to join it to the hat.

It you want it removable, I would skive the ends of everything to a taper, glue and sew them.

You could look at how bullet loops are made on gun belts for how those conchos might attach.

[chuck123wapati]

we could use a pic of the back of the hat band ends on the left of the head with some sort of embellishment, I don't see that so that's missing info on your project.

 on cutting the slots get a round punch the width of the intended slot and punch two holes that match the width of your concho strap then cut across with a knife creating the slot. Slot punches are pricey for one project when a cheap round punch and exacto knife aren't. One slot per concho the concho strap goes through the leather main strap then around the concho bar then back through the same slot under the main strap to the next concho. it could then be ended in the back with a bleed knot.

[fredk]

I assumed the OP was intending to use a buckled belt as that was what he showed

For information; these are some of the closures I've used;

On a concho ed repurposed belt; a buckle with a large keeper

Lacing, which went through the antler tips to hold them on, then criss-crossed. Enuf lacing so the band can fit on a larger hat

This one uses elastic cord glued to the band. Enuf elasticity to expand to fit a larger hat

 

 

[Gezzer]

I would round the ends of the main strap , then bleed knot the concho strap about 3 times and leave a short tail hanging .  

 

[tatanka48]

On 3/24/2025 at 12:35 PM, Rockrz said:

Wasn't sure which forum to put these question in....

I'm wanting to make my own hat band similar to the Donnie Van Zant hat band (see pic below), and I've already ordered some 1 1/4 inch Silver Slotted Star Conchos, and a black Buffalo Hide Leather belt that is 1 1/4 inches wide  (see attachments for pics)

All I still need is some leather that is flat black that's fits in to the slots on the conchos and some leather working tools to be able to punch a rectangular hole in the leather belt I'll be using.

I'll just run the thin leather strap thru each concho thru the holes in the belt where it will run on the back side of the belt all the way around where I'll have to figure out a way to fasten the back where the two ends come together.

Questions...

1) Where can I find a tool that is rectangular shaped once I find the exact size I'll be needing (I'll know once I measure the slots)

2) I was thinking of somehow tying the thin strap that will be routed thru as slotted concho where it all comes together in the back of the hat... so what are some ideas on how to do that?

One of the attachments to this message is a pic of the hat band I'm wanting to re-create since I cannot find anywhere that this can be purchased by itself without also buying the hat too which is pretty expensive

 

 

Rockrz,  me tinks you are overthinking this project a bit

 

if you are locked into the slotted conchos  you only need a small leather punch and a common box knife to create a common slit for running the attachment piece of thin leather thru the band 

 

the thin piece can be had frum most local auto upholstery shops out of their scrap pile OR frum a piece of black leather furniture set out on the curb for free/trash pick up (marketplace and craigslist are great sources ... rare is the day when i don't see at least one )

 

for the slits you only use 1-slit/concho where the thin strip comes up thru the slit then over the center bar in the concho and back thru the same slit and around the inside of the band to the next slit

 

here is the same principle used for the pins on a watch band

 

  

 

as for making a slit simply punch a small hole just a bit greater than the thickness of 2 pieces of the thin leather at each end of where you want your slit and using a box or exacto knife cut a straignt slit between the centers of the 2 holes. POC

 

this method has been used for way over a century where a belt runs thru a knife or axe sheath so the sheath can be carried 

 

the forces involved w/ knife and axe sheath carry far exceed those of your quest

 

slits can be seen here in belt axe sheath n camp knife sheath and special force's dagger

 

    

 

a BTW is in order here ...  conchos come w/ several different attachment methods

 

a loop for sewing one on like a button and a screw for heavier duty

 

i like the screws best because they only require a small hole to be punched in the leather/fabric as in a hatband i quickly made up back in the 1980's

 

  

 

GOOD LUCK W/ YOUR QUEST

 

leon

[Northmount]

On 3/24/2025 at 11:35 AM, Rockrz said:

Wasn't sure which forum to put these question in....

Moved, kind of fits with belts.  Purses, Wallets, Belts and Miscellaneous Pocket Items

 

[Rockrz]

Will be going back to the slotted conchos as I still want to duplicated the Donnie Van Zant hat band.

But meanwhile... 04/02/25

First hat band made (turned out pretty good!)
used... 1-1/4" The State of Texas Concho Double Rivet Back
mounted on to 1-1/4" wide 5-6 oz. (2-2.4mm) Black Leather Belt Blanks

The look is kinda similar to the Donnie Van Zant hat band

 

Edited April 14 by Rockrz

[Rockrz]

On 3/30/2025 at 11:47 AM, tatanka48 said:

i like the screws best because they only require a small hole to be punched in the leather/fabric as in a hatband i quickly made up back in the 1980's

The conchos I used have 2 posts and they have a rivet that goes on the back.

I put a little all purpose cement on the rivet before banging it in using my mallet

I like the duel post since it cannot turn and will always remain straight

[fredk]

On 4/14/2025 at 7:42 AM, Rockrz said:

Pretty snazzy

[Rockrz]

Thanks... I wonder if some people think maybe I'm a pimp er something 😅

[Rockrz]

OK, so I finally put together the hat band like the Donnie Van Zant hat band, but looping the leather thru the holes in the conchos don't hold the conchos very tight and they move up and down a bit.

The holes in the conchos are 3/8 inch so maybe I need to go with a larger leather strap... which would be the next size up from 3/8 inch?

From the pic below it doesn't look too bad, but in real life when I put this hat band on my hat some of them look uneven.

When I was punching the holes, it was kinda hard to make them all perfectly straight.  Maybe that was just me.

I was wondering if there was a way to use some wire to attach the concho to the leather strap maybe one on the upper side and one on the lower side wrapped around the center section of the concho, but I'd have to figure out a way to make the holes straight somehow 

If I used wire to attach them, the leather strap I install would cover up the wire.  Anybody ever attach conchos with wire and twist it on the back to secure it?

 

[Rockrz]

[fredk]

You could try using a wet strap for the conchos. Pull it up tight wet. Then when it dries out it will be even tighter

[Rockrz]

31 minutes ago, fredk said:

You could try using a wet strap for the conchos. Pull it up tight wet. Then when it dries out it will be even tighter

I never thought of that but it makes sense that it would be tighter.

How long to soak the strap in water?  Maybe over night?

[fredk]

Naa, it should only take a few minutes, 30 mins at most. Use warm water, with a tiny wee bit of dish-washing liquid soap in it. After soaking stretch it along its length in your hands, squeeze out excess water then lace it through the holes. As it dries it will stiffen up and shrink a wee bit tightening up

You can do this whether the strap is dyed or not

[Rockrz]

OK, thanks.

It's black so I'm assuming it's dyed unless it came from a black cow.