I enjoy walking in all its manifold forms, from a simple stroll in the woods to multi-day backpack excursions. Though by no means an extreme ultra-light enthusiast, from spring to fall my preference is to carry a pack weight of 12 lb/5.5 kg (before food and water), more or less. In recent years, I've rapidly moved to a philosophy of "lighter is better," within the constraints of budget and common sense.
Product information in brief
- Manufacturer: Tilley Endurables
- URL: http://www.tilley.com/
- Product: Tilley TH4 Hemp Hat
- Year of manufacture: 2005
- MSRP: US $69 (from website)
- Manufacturer's stated weight: 5.6 oz (159 g)
- Measured weight (analogue scale): 5.6 oz (159 g)
- Hat size (calculated by the online Tilley hat-size calculator: 7 3/8
- Fabric: hemp, natural color (cream)
- Fittings: 8 "British brass" grommets
- Sweatband: Hydrofil anti-sweat band
- Brim size: 3 1/2" (8.9 cm) front and rear, 2 1/2" (6.4 cm) sides
- Crown: padded with closed-cell polyethylene foam
Delivery and contents
The Tilley TH4 was safely received with an extensive (nay, astounding) array of literature. Five tags (including the size-tag) were attached to the hat. Additionally, a substantial and informative instruction manual, plus a sheet of eight "brag-tags" (more about this later) were housed in the pocket within the crown. Altogether this is one of the most thoroughly documented items of clothing I have ever encountered! A nice touch is that one tag states that the purchase of the hat enables the firm to give a donation to Street Kids International, a worthy cause indeedkudos to Alex Tilley (the owner of the firm) on this. Other tags detail the UV protection the hat offers, facts about the hemp fabric, and a tag listing the hat's features together with a photo of Alex Tilley and his daughter. Alex looks much like I would have expected from his literature, a thoroughly decent sort.
Warranty
The Tilley hat has a lifetime guarantee. As the owner's manual states "If your (unbleached) Tilley hat ever wears out, mail it to us with a $7.50 chequeor the number and expiry date of your credit cardto cover the shipping costs and we will replace it free. Or bring it to any store that sells the Hat; many will give you a new one." It's important to note the proviso about bleach; the manual firmly states "Do Not Bleach" as this will apparently discolor the hat. Note that sweat will also discolor hemp fabric in time, so frequent washing is important.
Within the crown of the hat it is stated that the hat is "insured against loss." I couldn't find any information on this so I called Tilley Endurables. After being greeted by the pleasant recorded voice of Mr. Tilley, I was swiftly connected to a customer service agent. She explained that, in the event of loss, the hat would (for five years) be replaced at half-cost, upon receipt of payment and a "straight-shooter's statement" i.e. a declaration that, upon one's oath and honor, one indeed lost it. All of this seems more than fair to me!
Website
The Tilley website is imposing and attractively designed, and contains just about anything anyone would ever need to know about Tilley hats (except, it seems, details regarding the Lifetime Guarantee, though they may be tucked away somewhere). Unfortunately, because of the site's complexity, some of this information is buried many levels down. I was forced to ask a fellow tester where the table of hat weights was hiding, as he had clearly found it; even after the explanation it took a moment to get there. I felt that if ever a website needed a site-map, this was it!
A key component of the online Tilley experience is the sizing calculator. For hats, the method of measurement is clearly illustrated. I took my head measure following the instructions, entered that into the appropriate field, and was told that I needed a 7 3/8. Tilley hats are intended to sit low and a little loose, and the hat I received does so, in a most satisfactory manner.
Introduction
Through a combination of astute marketing and an eye to quality and design, the Tilley hat has become something of an iconic object. Functionally, I look to a hiking hat to provide shade in summer (or warmth in winter) and to sop up sweat, all the while protecting my head from being prodded by sticks and branches. The Tilley hat appears to fit the bill well in this regard, but to boot it has a certain elegance, absent from my (very utilitarian) hiking headgear. In fact, it's a lot closer to my street hats (I've been an occasional hat wearer for years, on the contrarian basis that if few others are doing it, I will). I like the looks of it and, despite the fact that it's still winter, I intend to start wearing it out and about, on-trail and off.
Features and designinitial impressions

The Tilley TH4 hat is made from hemp fiber, in its natural color, which is an earthy cream. The fabric has an appealing, slightly irregular "nubby" weave. The quality of construction is high. No uneven stitching or irregular seams are to be seen. The brim of the hat is elliptical, and, as indicated in the section of measurements, is wider at the front and rear than at the sides. The shape of the brim is partly maintained by concentric rings of stitching. Though I could not see it when held against the light, I suspect that there is a layer of stiff interfacing between the two layers of fabric to provide further structure. The brim is stiff enough that it may be cocked at various angles. The rim is neatly edged with a bead of the same fabric. Though the hat should ideally be worn with the seam to the back, if the front of the headband is getting hot and sweaty the manual suggests reversing the hat; it is symmetrical.
The crown has eight brass fittings. Four of these are for the wind cord to pass through, the other four, of larger diameter, are for aeration. Within the crown is a soft circumferential sweatband, and at the top is a fabric pocket, to which is affixed the Tilley label in all its glory (it is wisely suggested that one's name and phone number be written on this). This pocket is used to retain an oval of closed-cell foam, which (the Tilley literature claims) enables the hat to float, and which has (again, as per the literature) saved the lives of Tilley owners when beset by blunt objects. The floatability I will certainly test; I draw the line at being hit with a blackjack to determine the efficacy of the padding.

This same pocket can be used to store credit cards, money and even a passport (I tried). It is neatly sealed with a strip of hook and loop fastener, so anything within should be quite secure. I'm unclear whether this "secret pocket" is sweat-proof, something to be checked. I suspect not, as a small resealable plastic bag is supplied. When received, the pocket contained the remarkable "Owner's Manual for the Tilley Hat" by Alex Tilley, as well as a set of eight "brag tags."
These are a clever and amusing advertising ploy. Each tag bears a customer endorsement on one side, often somewhat bizarre (I particularly liked the one from the elephant trainer); the reverse has a testimonial to the sterling character of the hat's wearer, and the instruction that (if the inquirer is given a brag tag to tell them how to obtain a Tilley hat) it is customary to provide a warm hug or stand the wearer a drink. Whether I will put this to the test remains to be seen, but the idea has promise!
Also within the crown is the wind cord. This can be tucked under the chin, and is adjustable via a pair of sliding knots. In truly alarming windstorms, the cord can be lengthened to allow a second loop to pass around the back of the head (all this is explained by the manual). If the wind is blowing hard enough to dislodge this arrangement, I may be in big trouble! There's also a strip of hook and loop fastener which can be used to keep the cord out of the way, or (at the suggestion of the manual), retain a pair of sunglasses tucked through the large grommets. I have tried this; it works. The size and model labels are also sewn in.
Some other details are worthy of note. "The fabric and
the style [underlined in manual] of Tilley Hats have been certified to block 98 percent of harmful UVA/UVB radiation, and deliver an ultraviolet protection factor (UPF) of 50+, the maximum rating given." Since I am careless about exposure to sun, this is definitely a good thing. The washing instructions provided can be best summarized as "wash often." The fabric of the hat has been "mercilessly pre-shrunk" so one need not fear the hat shrinking. It should, however, be hand-stretched if it feels a bit tight post-wash, and in fact it can be re-blocked (reshaped) by "putting your knee in the crown and pulling firmly on the opposite side" (all items in quotes are from the manual, as I'm trying to give a sense of its inimitable style). Machine washing (no bleach) is fine, but machine drying is out, unless one wishes "a misshapen hat lacking in joie de vivre." The fabric is water repellent, but will lose some of that ability through repeated washing. It's suggested that one periodically use a water repellency spray to renew the coating.
Future Testing Strategy
In my testing, I will examine the following aspects (and any other issues arising):
1. Does this hat adequately shade my face from glare? I'm fortunate in that I tend to tan, not peel (most of the time) but given contemporary UV concerns, does the UPF 50+ fabric protect my scalp and neck?
2. Also in regard to the loose fit, does the hat tend to fly off in an unexpected gust of wind? I lost a beloved Panama that wayit blew under a bus. Is the wind cord comfy in strong breezes?
3. I'm delighted to hear that the hat floats. I will wear it in the kayak and put that to the test.
4. The report period extends over a number of months in which we tend to receive storms. How well does the hat fare at keeping me reasonably dry?
5. I will also observe if indeed it keeps its shape in the rain. A wet, floppy hat is a deplorable thing.
6. I am a sweaty hiker. Even in sub-zero temperatures, my brow drips. I want to see how efficacious the anti-sweat band is. I hate sweat rolling into my eyes. It makes me squint, and squinting is alien to the elegance of this garment.
7. Speaking of sweat, how easily does it launder? How well do stains come out? And does it indeed retain its size and shape?
8. How well does the secret pocket keep things dry? How much will it accommodate before the appearance and comfort of the hat are spoiled?
9. The integral sunglasses attachment is handy. Does it work in the field (I have tried it only at home)? Will it accept most sizes of frames?
I want to very much thank Tilley Endurables and BackpackGearTest for providing the opportunity for this most enjoyable test.