Photos: Nick Fouquet

Before forming each hat, Fouquet steams beaver felt to make it malleable enough to shape by hand.  (Kirk McKoy / Los Angeles Times)

Fouquet cuts these oval pieces of wood to match his customers’ hat sizes so he can keep their measurements on hand.  (Kirk McKoy / Los Angeles Times)

Fouquet stretches felt over a mahogany block form, forming a hat with a rounded top and deep crease in the brim.  (Kirk McKoy / Los Angeles Times)

Fouquet uses fire and smoke to lend age and character to some of his custom-made hats.  (Kirk McKoy / Los Angeles Times)

After pressing and shaping the felt, Fouquet sews an interior sweat band and hat band onto each of his hats.  (Kirk McKoy / Los Angeles Times)

Fouquet sews on the interior sweat band for the hat.   (Kirk McKoy / Los Angeles Times)

Nick Fouquet tries on one of his hats.  (Kirk McKoy / Los Angeles Times)