Zara Phillips's Wedding

Catherine, Duchess of Cambridge is a master at recycling looks from her own closet, but when it comes to her hats, it seems this royal is happy to splurge.

At the wedding of Prince William's cousin Zara Phillips to Mike Tindall, Kate accessorized her cream Collette Dinnigan French lace dress and Day Birger et Mikkelsen brocade coat (both worn in 2006) with a brand new, bespoke hat by British milliner Gina Foster.

Retailing for about $675, the natural straw coulis, called "Launceston Place," was customized by the duchess in a whirlwind visit to the hatmaker just 10 days before the nuptials. "She rang and asked to come in, then she tried a few on and we went from there," Foster tells PEOPLE from her tiny boutique in Kensington (a mere minutes walk from Kate's new apartment at Kensington Palace).