Straw cowboy hats are a summer staple, offering classic western style and essential sun protection during warm weather. Resistol transforms raw straw into iconic cowboy hats that blend durability with handcrafted elegance.

The process of creating a straw hat begins in Ecuador or across the ocean where straw is harvested. Skilled artisans with generations of weaving experience prepare the straw through a detailed process of stripping, washing, cooking, dyeing and drying. Once properly prepared, the straw is bundled and delivered to master weavers.

Each weaver brings their own regional technique to the process, creating intricate patterns that take between one and three days to complete, depending on the complexity. This craftsmanship results in the straw “bodies” that will eventually become cowboy hats.
Once the woven bodies arrive at Resistol in Garland, Texas, they undergo several transformational stages.

The first stage is blocking, where the straw body is placed on a custom sized mold and shaped under heat and pressure to form the recognizable cowboy hat structure.

A metal wire is placed on the outside of the brim and then welted over. This helps to maintain the structure of the hat brim shape throughout its life in the hot summer heat.

Once shaped, the hat is expertly trimmed to remove any excess material and refine the edges for a clean, polished look. Next, the hat is stiffened with lacquer to ensure the hat retains its shape and durability over time.

Finally, the straw hat is completed with a sweatband, hat band, and buckle set, adding the finishing touches of style and functionality.

Every Resistol straw hat includes thoughtful hand-finished elements.
This sweatband is meticulously hand-sewn and stamped with the Resistol trademark, a symbol of craftsmanship and excellence that reflects the quality of the hat.

Each buckle set is carefully assembled and placed by hand, ensuring precision and attention to detail. Resistol completes their cowboy hats with exquisite detailing on their buckle sets, adding a touch of elegance and craftsmanship to the final product. These buckle sets serve as a signature finishing touch.

An essential step in transforming your straw cowboy hat is the application of Resistol’s exclusive finish. The Tuff-Anuff straw collection by Resistol is designed to stand the test of time, offering unmatched durability. Each hat is carefully hand-dipped in Resistol’s proprietary lacquer, which provides superior water resistance, easy cleaning, and long-lasting protection, ensuring your hat stays in excellent condition for years to come.

The Dry-Lex sweatband used in Resistol hats is a breakthrough in comfort and performance. Featuring a patented lining system, it effectively wicks away sweat, keeping you cool and dry throughout the day. This innovative design ensures lasting comfort, making it a key feature in Resistol's commitment to quality and functionality.

To keep your Resistol straw cowboy hat looking its best, follow these care tips:

• Use a clean, damp cloth to gently remove dust and dirt
  Avoid exposing your hat to excessive heat like radiators, stoves or car windows
• If your hat gets wet, shake off excess water
• Occasionally flip the sweatband down between wears to prevent sweat and hair products from seeping into the straw

As for the million dollar question, when should you switch to your straw cowboy hat? Read more here.