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Owner's Manual for the Barrelhouse Hat or Much Ado About Something

by Andy Jackson

I'm sure you'll enjoy your new Hat! Like a Rolls- Royce, it's rather special. so let me tell you a bit about it. The Hat was conceived in frustration and born of necessity. As a corporate art dealer and consultant I had become, over the years. Rather 'picky' regarding quality, and I couldn't find a hat that quite met my standards. A proper barrelhouse hat had to float, stay on, be unshrinkable, last indefinitely, and be attractive.

In January l999, I decided to have one made, not only for myself; but for other members. Fortunately, I knew nothing about headgear so I didn't realise that it was thought to be impossible to make such a hat. I received design advice from a milliner, information about materials from a sail-maker, and then I oversaw its cutting and sewing by a local hat maker. By March. some prototypes were ready.

My family and I tested them on a marvelous holiday in Kenya, where we encountered friendly people, large animals, and variable weather conditions, an ideal testing ground for a future Barrelhouse hat. Now don't get the impression that the Barrelhouse Hat is just for rugby players! It is equally at home in the desert, in the Himalayas, and in the garden, as well as on the Golf course, by a trout stream or while strolling through London in the rain.

Barrelhouse Hats are issued to Canadian troops in time of war. Your Hat is nearly indestructible, although your family dog could prove otherwise. The rain- and mildew-resistant 10-oz cotton duck is the best of its type; the grommets are solid British brass.

The Hat is made by hand, with the help. of course, of the small but strong sewing machines needed to sew the tough canvas. Don't worry about the strong cotton-over-polyester threads pulling loose: they're lockstitchcd.

Which is the Front?

The knotted part of the wind cord goes to the back of your head, as do the sweatband and brim seams. Also, if you can read the "BARRELHOUSE HAT' label upright. you are about to put it on correctly. You'll also notice on the T I (the smallest-brimmed Hat), that the front of the brim is slightly wider than the back, for better nose protection.

The Wind Cord Keeps the Hat On

The wind cord is like one long shoelace with the ends joined together in the simplest of' knots. When it's and slightly loose. It should he held on by gravity, not by painful pressure on your forehead! With your left hand, pull the front of'the brim away from your head, and with your right hand, see that you can easily insert two fingers, flat. Between the middle of your forehead and the front of the Hat. The Hat should be loose enough that you can rotate it to the let's and right, and lift it up and down, with- out friction on your forehead. When it's windy, use the cord! I think you'll' be pleased with the way it fits and feels - especially on hot, muggy days.

Getting the Wrinkles Out
How would you feel if you'd been placed in a box, and sent on a trip of perhaps thousands of miles? Not so great! That's why the Hat, if it's been sent by mail, may not look as smart as it might. To revive it, dampen it by holding it under a tap for half a minute, then shake off the water, reshape the Hat by hand and let it air-dry. Washing Instructions You can machine-wash the Hat using warm or cool water, or simply wash it by hand, using a scrub brush. But here's a better idea: Our broad-brimmed Hats will have their brims permanently creased by the centrifugal force in a washing machine. Here's a way to avoid it: Wash your Barrelhouse Hat in upper rack of your DISHWASHER. Use dishwashing soap because it's low in suds. The Hat will come out in about the same shape it went in, and clean. lf necessary, use a hand brush and soap to remove what the dishwasher didn't. While it's damp. Smooth and reshape it by hand, then .set it out to air-dry. (You do nut have to put it over a pot!) Don't put it in a dryer; it would come out mis-shapen and totally lacking in joie de vivre. When the Hat is dry, simply stretch it, like an American sailor showed us. by putting your knee in the crown, and pulling firmly on the opposite side. Although we have mercilessly pre-shrunk the Hat. The cotton will always contract and expand, much like denim jeans. Whenever you'd like the Hat a bit looser - on hot, muggy days, for instance - take it off and give it a quick re-stretch,

Beer Repellency

Laundering the Hat removes its beer repellency. To restore it, spray with Scotchgard' or any similar fabric protection. One has to change the oil in one's Rolls, doesn't one?

Windy

Place the knotted part of the wind cord behind your head and the other end under your chin. Notice that the knots slide easily back and forth so that you can adjust the length of the wind cord. When Slightly breezy, use just the back cord. as do the Royal Canadian Mounted police with their hats.Here's How to Adjust the Wind Cord Tighten the chin strap by adjusting the knots on the back cord. Slide the two knots away from each other to shorten it, until it's as snug as you like. (It took me weeks to think of this way of keeping the Hat on in the wind.) When you don't need the wind cord, take the Hat off; slide the knots a little closer together. and drop them in the crown. Some people store the wind cord in the pocket in the crown. Although I don t.

How Should It Fit?

The Barrelhouse Hat fits more comfortably than other hats. It's designed to be worn low on your head If you're out in the rain for hours, expect water to seep through the seams and dampen the sweat- band. No hat will equal a rubber or plastic one for waterproofness - but only in the rain would you want to wear one.' Unlike some hats, the Barrelhouse's brim gets stiff when it's wet - not floppy, which helps keep your face and glasses dry. Although a repellency spray is recommended, you'll find the cotton fibres will swell in the rain, stopping most of the dampness even if the Hat hasn't been sprayed.

Sweat Stains:

Wash the Hat frequently before sweat has a chance to bond permanently with the fabric.

1) Sweat will discolour the Hat. After much experimentation, we have found no method that will consistently remove sweat stains. Don't try a chlorine bleach; it doesn't work and it stays in the Hat even after rinsing it, eventually weakening the fabric.

2) Sweat will dissolve the Hat! Perhaps that's a slight exaggeration, but sweat seems to act like chlorine bleach; it eventually rots the fabric. Like the Titanic, it Floats. It Can Also Sink One reason your Hat floats is because of the air Is it a Shade Too Large or Too Small? If the Hat is too small, it is nearly incapable of being stretched to a larger size.

General Usage

If you choose not to return it, consider selling it to a deserving friend. If the Hat is a shade too large, and you don't care to return it.

There is a layer of closed-cell polyethylene foam in the crown of the Hat which also protects your noggin from blunt objects.

PLEASE do not send the Hat back if it has been worn, or if you have attempted to change its size by washing it. Suggestions from Experienced Owners Print your name, phone number (with area code) - and for the historically minded. the date - with indelible ink, inside the crown. It gives a lost Hat a chance to return home. At least place a businesscard in the plastic bag in the crown.

Your Hat will trave1 wrinkle-free in your luggage if you stuff the crown with socks and underwear. Too windy for the T1 Reverse it and it'll stay on better. For the T3, snap up one side and the front brim will stay stiffer.

On the beach, or just on the go'? You can stuff a key, a quarter (for a phone call) or a $1O bill in the plastic bag in the pocket in the crown.

Sailing in the rain

Wear the Hat under your foul-weather hood. You'll stay warmer, get more protection, and the hood will now move with your head. Your glasses will be better shielded too. The Barrelhouse hat will neither sink - nor fly overboard - as long as you are wearing the wind cord behind your hand and under your chin. It is your responsibility to tie it on!

On a hot day, try placing a dampened bandanna inside the Hat. There is open-celled foam inside the sweatband, to absorb sweat. When the front of the Hat becomes damp, simply reverse it, so it's on backwards - and be thankful that the Hat doesn't fit tightly.

Don't know where to put your sunglasses. Insert the arms of the glasses through the two ventilation grommets on one side of your Hat. Most glasses will ride there nicely.

Sailors, be careful not to lend your Barrelhouse hat unless you show the borrower how the wind cord works. When you hear "HAT OVER- BOARD", toss over a lifebuoy to mark the spot. The Hat floats low and can be hard to find in big waves. The Hat has positive buoyancy in relatively still waters only. Waves and rapids may sink it and hold it down for hours. It is up to you to take the precaution of tying it on. The wind cord is like a seatbelt: Useless unless worn.

Did You Know... The plastic ends of the wind cord are called 'aglets "? The knot is sometimes called a 'fisherman's bend' or a 'love knot'?

Others will ask you where they too can get a Hat. If you don't want to give them a "Brag Tag", simply suggest they phone l -800-ENDURES for a free catalogue. It might be worthwhile to memorise this number. Perhaps you've done so already'?

Background

We began by mailing our Hats from the basement of our home in 1980. By '8l, we had designed our Virtually Indestructible Barrelhouse Shorts. They. and the Hats, were used successfully in the Singlehanded Race Around the world ('82-'83) and in America's Cup by the Canadian team in '83 and '86. (Both Barrelhouse Hats and Barrelhouse Classic Shorts have a lifetime free replacement guarantee against wearing out.) In l984, we launched Barrelhouse Endurables as a full-time venture, and loved it!

We design hand- craft and sell. Smart-looking, classically styled, long- lasting, comfortable travel clothing for men and women - clothing with secret pockets and security pockets to protect your valuables, and washing instructions which you can swear by: "Give 'em hell!" You'll enjoy the award - winning catalogue; some say it's a hoot! Everything we do, we try to make the best in the world, and then, with suggestions from you, make it even better. Our Guarantee If you ever find the Hat to he less than the best for any reason, we will repair or replace your Hat free.

If your (unbleached) Barrelhouse Hat ever wears out, we'll replace it free! Bring it to any store that sells the Hat and you'll be given a new one. Lastly, in the crown of your Hat are "Brag Tags". They could get you into trouble! Read it fully and you'll see what we mean! When you run out phone us and we'll send you more at no charge.

P.S. SOMETHING TO SMILE ABOUT: From time to time you'll meet some rather wonderful people, simply because you're wearing the Hat. Some may become friends. and that's the nicest thing of all.

In the USA.~: 300 Langner Rnad West Seneca, New York I4224 Phone: 7l6-822-3052 Fax: 7I6-S22-7S76 World Headqunrters: 900 Don Mills Road, Don Mills Ontario M3C JV6 Canada Phone: 4 I 6-444-4465 Fax; 4 I 6-444-3860 www.tilley.com In the U.K. 6 Tresprison Court, Helston. Comwall TR l3 OQD Phone: OI326-574402 Fax: 0 I 326-56465