Tilley sun hats. Those words seem to go together like Osprey and backpacks, like Teva and water shoes, like Swiftwick and biking socks, like Coghlan’s and camping gadgets.
For those who want a well-constructed hat that is going to hold up well over the years, buying something from Tilley Endurables has long been the obvious choice. My colleague Kara loved the Tilley hemp hat she tried out last year. I’ve been trying out one of their models for a month now—the organic cotton Airflo hat—and I get what all the fuss is about.
The company makes it clear that this is not your average afterthought sun hat made on the other side of the world. “Handcrafted with Canadian persnicketiness,” these even come with their own instruction manual. Your hat will fit if you measure your head before ordering: they make them in 13 standard hat sizes. Their guarantee says they’ll replace it if something falls apart, but they bet you won’t be able to wear it out. Here’s what happens if you do:
“If you ever succeed in wearing out your Tilley Hat (and some have), send us the remains and we will replace it free. If you want to keep your faithful, old, worn-out friend, tell us and we’ll return it to you. We understand.”
If you lose it, they’ll even replace it for 50% of the cost. They trust you.
But anyway, what about this particular model? Well the air flow part of the Airflo really works. Mesh along the top allows a breeze to cool your sweaty brow while the solid part on the top keeps those of us with sparse follicles from getting a sunburn. There are shoelace-type straps to keep it on your head when it’s windy, but it’s easy to tuck them away or even remove them completely when not needed. As you can tell from the model photo here, the brim on this one is not as huge as with many sun hats. That may mean a little less protection, but your brim doesn’t bang people in the face in a crowd.
This model is made from organic cotton, but it’s been aggressively pre-shrunk so you can wash it without worry. As someone who has had several travel hats become too small to wear anymore, I can promise this is a big deal when it comes to longevity. It does a reasonably good job of keeping your head dry in a drizzle and there’s a secret pocket inside for that extra stash of cash. And it floats!
Tilley Endurables makes a wide variety of travel hats for men and women, so if you don’t like this model there are plenty more to choose from. Different brim sizes, different properties, and different fabrics. You can get a hat with a neck flap, one with InsectShield protection baked in, or one made of waterproof nylon. All carefully designed and constructed and built to fit perfectly.
Naturally all this care means a higher price point than some knock-0ff hat made in China, but this Airflo T5MO one lists for $77—about what I paid for my last pair of sneakers. (Which were made in China.) Visit your local retailer to see different styles in person, or order from one of these online shops.



#1 by Ramie - April 30th, 2010 at 16:28
I’ve had a Tilley hat for close to 10 years now that I’ve taken to at least that many countries. It looks a little worn, but it still fits!
#2 by Jack Senior - June 1st, 2011 at 09:49
Thats quite a guarantee Tilley are offering, its good to see an company standing behind their products like that. I think one of these could be just what I’m looking for