This project was started from a request on the ShopBot forum. It did not pan out but I had some fun and learning experiences from it like slicing a model. Here are a few pictures of the final product. The one with the brim was just for fun and not really a hat block - the domed shape one without a brim is close to the actual hat block design they were looking for.
Here is the original hat picture:
And the blocks I created.