I've had a "cowboy" hat for a couple years. It's wool felt, pretty nice quality, but the fit is just a touch too small. Is there any way to "stretch" it a bit so that it fits more comfortable, and will get some decent use instead of being a shelf queen?

It's not a matter of the headband or chin strap being too tight, the actual crown of the hat is snug. I know if a wool cap is too large you can dunk it in hot water and then wear it for a while until it "shrinks" to your head. What about the opposite direction?

You probably want someone like this:
http://www.henrythehatterdetroit.com/ind...rt&Itemid=1
to block or renovate the hat.
I don't know Henry, I just Googled "hatters detroit."

Yeah, this is one you want to let a pro do. They have the steaming machines and blocks/stretchers to do the work correctly.

Yup. If it was just the sweatband, most western wear stores have stretchers, but for the crown, it needs a real pro. I once watched such a guy "making" custom hats for walk up customers at a gun show. He started out with something that looked a lot like what Hoss Cartwright used to wear, then put the crown and brim shapes on that the customer wanted. Very interesting to watch...

Aw crud... ok, thanks guys.

Yo could try this - SLOW and EASY, lots of steam:
http://www.villagehatshop.com/jack_stretcher.html.

Usual disclaimers: no connection, no experience with this company, etc., etc.

I have used similar products in the past when I wore hats more frequently.

If you are finding it unwearable maybe you should just take the sweat band out.
Newer Stetsons use a plastic material for the sweat band that does not stretch at all and is not really comfortable.
If yours is silk lined you will likely lose the lining cloth if you do this, but I found mine to be much more comfortable without the sweat band.

You might want to add a proper hatband, one that you can tighten, if it feels too large without the sweatband inside of it.
The hatband on mine was just a little strip of felt they stuck on to cover the line where they sewed the sweatband into the hat.
It was easily replaced with an adjustable band.

Mine is not exactly a dress or uniform item though.

It's not actually a stetson, just a similar style. No headband, just my head in contact with the felt.

It fits (sorta), it's just really snug. Like, gives me a headache after a while.

Steam it and stretch it over your knee.
A boiling teapot will give you enough steam. Hold it over the steam coming out the spout.
The felt should be hot to the touch but not boiling hot.
Steam mostly where you need to stretch it
You might have to pull fairly hard to stretch it enough, just stretch it a bit at a time though until it fits right.
The hot steam will let you reshape the crown and brim too if you need to.

edit.
Stetsons are way overpriced.
Smithbuilt or Baily are every bit as good.

LOL

I was looking at some last night actually. $49.99. I think I bought mine, in Yosemite, for $39.99. Wish I knew offhand what brand it was!