Brands we work with
Ready to create your custom 5-panel hats?
Design Online
Use our online customizer to design your custom 5-panel hat — choose your colours, upload your logo, and preview your design.
Request a Mock-Up
Not sure where to start? Send us your logo and we'll put together a free mock-up of your custom 5-panel hats within 48 hours. No obligation.
"I just got my hats in now and they look absolutely fantastic. I'm so unbelievably happy with these."
- Devon / The Mean Green Weed-Killing Machine
About the 5-Panel Hat
Made with the AJM 6F080M — a structured A-frame cap with a wide, uninterrupted front panel and flat brim. No centre seam means your leather patch sits clean and undivided. Adjustable snapback closure, one size fits most. Available in 9 colours including six two-tone colourways.
Heat-Stamped, Not Lasered
Your logo is pressed into full-grain leather using a custom brass die — not burned in with a laser. The result is a deep, textured impression with natural character. It won't fade, crack, or peel. The kind of quality people notice.
Handmade in Ottawa, Canada
Our custom 5-panel hats are handcrafted in our Ottawa workshop. From cutting the leather to milling your brass stamp and heat-stamping each patch, we handle every step. Lifetime craftsmanship guarantee — if we built it wrong, we'll make it right.
What our customers are saying
start designing your custom 5-panel hats-
★★★★★
We all love the leather patch hats, it's a quality product for sure! Everyone has been asking me for them and I'll need to order another batch soon!
- Kurtis B. / Capital Film Wranglers -
★★★★★
Hats are selling like hot cakes.
Everyone is in love with them!
- Melissa S. / Broadhead Beer -
★★★★★
I couldn't be happier with how our custom hats turned out. The hats look great and and they're a unique way to showcase my business. I have received so many comments about the quality of the leather patch.
- Chris / Chris Allard Mortgage Team -
★★★★★
Working with Byward Outfitters was a pleasure! Their customer service was excellent, which made the entire process, from design to delivery, completely effortless.
- Julien D. / Apt613
How It Works
Start your design
Use our online customizer to design your custom 5-panel hat, or send us your logo and we'll put together a free mock-up within 48 hours.
Approve & Order
Review your design, confirm the details, and place your order. Minimum order is just 5 hats.
Receive & Enjoy
We heat-stamp your leather patches by hand and ship within 2–3 weeks. Quality checked and ready to wear.
For full pricing, process details, and FAQ, see our Custom Leather Patch Hats page.
Request a Mock-Up
Let us help you get started; fill out the form or set up a call with us
About Our Custom 5-Panel Hats
Our custom 5-panel hats are made with the AJM 6F080M — a structured A-frame cap that's become a favourite for brands wanting a modern alternative to the classic trucker. The wide, uninterrupted front panel is the best canvas for a custom logo — no centre seam splitting your design. Each hat features a heat-stamped full-grain leather patch with your logo, crafted by hand in our Ottawa workshop. With 9 colours, 10+ patch shapes, and a 5-hat minimum, custom 5-panel hats from Byward Outfitters work for outdoor brands, creative studios, and businesses that want a distinct, contemporary look. Unlike embroidered 5-panel hats, our leather patches are heat-stamped for a deep, lasting impression that won't fade, crack, or peel. Design online or send us your logo for a free mock-up.
What's the difference between a 5-panel hat and a trucker hat?
5-panel hats have a single wide front panel with no centre seam and an A-frame structure that sits higher on the head. Trucker hats have 6 panels with a centre seam and a mesh back. Both feature an adjustable snapback closure and take a leather patch equally well.
How many colours are available for custom 5-panel hats?
9 colours including six two-tone colourways like Navy/Putty, Black/Putty, and Forest/Putty. You can browse all available options in our online customizer.
What's the minimum order for custom 5-panel hats?
Just 5 hats. The more you order, the lower the price per hat.
Other Custom Hat Styles
Trucker Hat
Classic mesh-back trucker. Breathable, adjustable, and built for everyday wear.
Dad Hat
Relaxed fit, curved brim, all-day comfort. The laid-back option.
Flat Brim
Classic mesh-back trucker. Breathable, adjustable, and built for everyday wear.
Toque
Warm, classic cuff. Heat-stamped leather patch. A Canadian winter staple.
All Custom Hat Styles
See all styles, pricing, and FAQ.