Case Study:
The Making of the Giant Smithbilt Cowboy Hat

From Concept to Completion: Bringing a Calgary Icon to Life

Project Overview

Commissioned by Smithbilt Hats Inc., this project aimed to create a larger-than-life tribute to Calgary’s cowboy heritage. Standing at 16 feet wide by 20 feet long and covering nearly 1,000 square feet, the Giant Smithbilt Cowboy Hat is the largest and most realistic cowboy hat in the world. Crafted with precision and creativity, this iconic piece will become a landmark of both tradition and craftsmanship.

Project details:
Client: Smithbilt Hats Inc.
Location:  (address) Calgary, Alberta
Project Type: Giant, Ultra Realistic Cowboy Hat
Specifications:

Concept and Design: Crafting a Vision

The creative process began with concept drawings and digital renderings to visualize the final product. Using a hyper-realistic laser scan of an authentic Smithbilt White Cowboy Hat, we translated this traditional symbol into a larger-than-life representation. Attention was given to every curve, crease, and detail to ensure accuracy and evoke the spirit of Calgary’s cowboy culture.

Engineering & Materials: Building for Durability

The Giant Smithbilt Cowboy Hat required detailed engineering to ensure stability, durability, and weather resistance. Constructed from CNC-milled EPS (expanded polystyrene) and coated with polyurea for a durable finish, the structure is built to withstand the elements while maintaining its realistic shape and design. Special care was taken to balance the hat’s weight distribution and to securely mount it to its final installation site.

Fabrication: From Concept to Reality

Turning vision into reality, the fabrication process involved CNC-milling the EPS to match the digital design precisely. Our skilled team then carefully assembled the components, shaping and refining the structure to capture every detail. The polyurea coating was applied to give the hat a smooth finish, adding both realism and protection.

Installation: Bringing the Hat to Life

Installation day was the culmination of months of planning, design, and fabrication. Carefully transported to the new Smithbilt Hat store location, the hat was installed on September 28th at 10:00 a.m. with precision. Our team ensured every detail was secured and aligned, transforming the space and giving the new store a truly memorable and iconic feature.

Challenges & Solutions: Overcoming Obstacles

Every large-scale project comes with its challenges. From precise material shaping to secure mounting, our team tackled each obstacle head-on. The polyurea coating added both aesthetic value and weatherproofing, while engineering adjustments ensured stability and longevity for the giant hat.

The Final Product: An Iconic Landmark

The completed Giant Smithbilt Cowboy Hat stands as a testament to craftsmanship, creativity, and tradition. Now a centerpiece at the new Smithbilt Hat store, it honors Calgary’s heritage while showcasing the innovation and skill of Porterfield Studios. This project reflects our dedication to pushing design boundaries and creating memorable experiences.

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