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You can get one on etsy. (I wasn't lying in the other thread and I have no affliation with the site other than I freaking love to buy stuff off there.) I just got this awesome for myself: viking hat
Etsy is pretty cool but I want something more heavy duty and technical. I think I'm going to end up making a leather tunturi hat with a polar fleece lining, and use a hand awl to sew it together.
I can’t top that, although I’m not far behind you as my head measures 63cm (25 inches). Even at that size, hats that fit are hard to find: I sympathize.
Last year, tired of only being able to wear beanies, I scoured the internets in search of headwear that I could squeeze my bulbous skull into, and special-ordered a Montecristi (Panama) hat from these people; a Borsalino 'Como' fedora; and an Irish patchwork flat cap.
My head is tiny. 20 inches (52 cm) when I was last measured for a hat. Hat store people pity me, because it was a very common size in the 60s (they even had size 50, that's 19 inches) in ladies hats back then, but you simply can not find hats in anything other than "one size fits all" 58 cm these days. Argh. I'm a hat person too, I'd wear a hat every day if I could find any that fit.
On the upide, we all know small hedas are good when playing hide an seek or generally getting through small spaces. Anything I can get my head through, I can get my body through. This means I can squeeze through gates like the ten year old kids!
Hang on, that's 64.77 centimeters. One of my exes had size 68 in hats which is huger (consider yourself topped) and rummaging through the vintage bins I found him at least five hats from the 60s. Again, there were no one size fits all back then. Life was good.
I've got a pretty good-sized head, and, in my limited experience, the largest technical winter hats are North Face size Ls (Mountain Hardwear and Patagonia size Ls are slightly smaller, and anything one-size-fits-all is significantly smaller). Wild guess, though--you can find even larger sizes through hunting companies. (Also, I'm starting to want one of those Irish patchwork caps.)
I'm cranially endowed, as well. To top it off (heh), I have big hair. Thick, coarse, wavy. I have a couple of slouchy fleece hats that fit, but those One-Size women's hats are useless. The felt idea from your thread sounds great.