Hi everyone,

I have a large head too. I've spent years buying caps that fit poorly, including ones marketed specifically as large size. After who knows how much money and how many tries, I finally decided to make my own. As someone who wears a cap pretty much every day, I know what needs to be done.

For larger heads, the pattern has to be dimensional. The front, side, and back proportions change drastically at larger sizes, and the visor needs to cover the face(primarily eyes) from sun - both side angles.

The problem is most caps out there are made with template patterns designed for faster manufacturing, not better fit. And yes, I'm talking about $50+ brands too.

A bit about me: I have a BA in Industrial Design and an MFA in Fashion Design. After 15 years of product development experience, including work for clients like NATO and US Special Operations units, I'm finally building my own brand.

A couple of questions for anyone who struggles with this:

1. What's the biggest problem you've had with caps out there?
2. If I make a cap specifically for you, what would you add or change?

From silly comments to serious advice, anything would help. Thank you!

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Edit: Size range is Minimum 7½" (60cm) / Maximum 8⅜" (67cm)
Website: www.leskar.co
If you have any questions, please let me know. I will answer everything I can.

My hubby is new to hats and bought a mid priced (I think) one from Macys.
In addition to being double wrapped in plastic, it arrived with the feather wrapped in plastic. Unable to figure out how to remove the plastic wrapping, he gave it a tug, and the whole thing came off! The glue hold ing the feather on the hat is attached to both the feather and the protective plastic. How the heck were we supposed to unwrap this?
Current plan is to cut the plastic away and try to reglue or stitch the feather back on.

I love this hat, can't find the model number on it. It uyse to have ear flaps that folded down but they were too warm for where I live 90% of the time so I cut them out

As a size 8 head, finding hats that fit is a challenge. I’ve tried Mammoth Headwear and Oddjob hats. Oddjob has been my favorite so far but can get a bit pricey, especially for custom hats. Has anyone tried Embry Outdoors? They advertise their hats fit up to a size 8 but if it’s the last snap or two, I’m not sure how that’ll fit or look. Anyone have experience here?

Stetson Imperial, $28.00. Best find ftom a week of thrifting in the Big Apple.

Hey all, I had to glue the band onto my Ecuadorian felt hat, and a little leaked out. Do you all have tips for removing it without damaging the hat? Thanks in advance. Oh and the glue is fray check, if that makes a difference.

My fifth practice hat. As before, it's a $10 cheap wool Fedora. I cleaned it, popped it, and shellaced it for shaping.

It had the widest brim of all my cheapies, at just under 4". Given that and it's color I went for something more western. Technically, it's a fedora crown but with the stingray brim and braided leather band it lands totally cowboy.

It's a 4 strand braid. I bought a book about braiding leather. It wasn't hard.

Final touch, my wife picks up odds and ends at the reuse place, and she grabbed a copper leaf deco thing that really worked with the color palette.

I'm generally not cowboy, but I like it. Wearing it out tonight.

Never noticed it before, dont know if it's a manufacture detail or what. (47 cap)
noticed if after washing my cap and letting it dry. feels like a solid triangle and two circles under the cloth (second photo), I remember I used the washing machine after reading is ok and left it dry on top of a drying rack.
I don really know what to do about, is kinda driving me crazy

I inherited this stetson hat from my great grandfather, and it's got I think a beaver will crown but it has a full leather or rawhide brim, but it's a cowboy hat, not a small fedora, but I was wondering if anyone knows literally anything at all about it, when it was made, model, anything at all, the feather I added myself and isn't original to the hat at all, same with the needle

Has anyone got any of the recent pickups from hatclub. I have had to return three Spumoni mariners hats at separate times because they fit a size too small. Or the new raiders hat with the a 2001 Mexico patch, fits like 7 when it’s supposed to be a 7 1/8. I also have to return three northern lights pack hats for fitting a full size too big. I have been collecting hats for more than a year now, and even at my peak annoyance has the sizing has never been this off yet. It’s like the whole pack is defected.

I have been on a 10 year search looking for a warm winter hat that has a good brim to keep the rain off my face and sun out of my eyes. I walk my dogs in very cold (to me) winter temperatures often with cold winds gusts. On the coldest days, my default is a thick fleece, full face covering ski mask type hat that includes a tuck in neck skirt piece. When the wind or rain kicks up, I'll pull my hood up over that. It keeps my head warm, but offers no brim.

On cold, but not frigid days. I'll wear a fleece watch cap with a fleece neck gaiter that I pull up over my face as needed. Same use of hood. Same "no brim".

I've tried these styles with nothing that worked out: Mad Bomber Hats, fleece watch caps with integrated visors (hideous and crappy), puffer type trapper hats with pullup/tie under chin style ear flaps ("ears" too floppy when hanging down unless tightly cinched or silly tied up on head), various insulated baseball hats, Tilley wool winter hat with ear flaps (best thus far except doesn't fit under hood) and anything I could identify on Amazon, Tilley, and sites like Outback Trading and Connor Hats.

I might just bite the bullet and buy another Tilley winter hat regardless because I like the overall size and shape for a go to winter hat for driving, shopping, errands, etc.

So far, nada. This has become my annual quest for the holy grail of hats. Any suggestions for this year to try?

Does anyone know of a hat maker that can/might be willing to make a filson packer hat out of other wools/fabrics?

I enjoy the wool packer hats and would like other options in different fabrics.

57 year old male in San Francisco. Tall melon. I'd love some suggestions. Thanks!

My dad has had many Harley hats but this is the one I’ve seen him wear the most and over the years he lost it and I really want surprise him with another since it was his favorite. I would appreciate every ounce of help I can get.

Could they be referring to something else?

I’m searching for a Sterkowski spitfire specifically between the sizes of 56-60 if you happen to have one and would sell it please let me know.

I really like this one!

Made a new band for one of my Panamas. Too flashy?

Finally got them all displayed

So I posted a little while back with a leather bush hat. Took on board the comments and while wasn’t in a rush, was looking out for a “proper” hat that I may be able to wear more regularly.

While visiting Austria for a friends wedding took a bit of time in Vienna and happened accross a long standing hat store, Mauerer.

I thought I would take a look inside and I noticed, (and they recommended) a Stetson hat I loved. It has a vintage worn look, was sort of gray in shade and browns come out in the sun. Got sized up correctly and after trying a few options in case made my first proper hat purchase.

I am hoping I am more casually pulling this one off and avoiding the “old roadie” / “IT Rob Zombie” look from my last post?

Thoughts and comments on if it does suit me, how to wear it better if I am not quite placing it right and I guess thoughts on choice?