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I have made several hats (and a pair of shoes!) using this method, all with 100% synthetic felt. It works perfectly for the bowl of the hat--stretches like crazy! However, for the brim, use just a single layer of felt, stiffened with glue or starch or a sewn-in hat wire (ironing two wet, gluey layers together will not work with this felt; I think you need the stretching to get them to bond).

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