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    Hats for Big Heads: Sizes XXL to XXXL (24"-25.6" / 61-65cm)

    If you wear size 7 5/8 or larger, you already know the problem: most hats stop at size 7 5/8, leaving you with tight-fitting crowns that sit too high, dig into your temples, and leave red marks across your forehead. Head sizes above 23.375 inches are considered large, yet one-size-fits-most hats typically max out at 23 inches, forcing people with larger heads to compromise on both fit and style.

    Conner Hats offers 45 styles in XXL and XXXL sizes—handmade hats designed with deeper crowns, wider circumferences, and adjustable sizing systems. Our collection includes Australian leather outback hats, breathable mesh hiking styles, waterproof cotton adventurer hats, and crushable travel options in sizes up to XXXL (25.6" / 65cm). Each hat is constructed from sustainable materials—organic cotton, hemp, recycled polyester, cruelty-free wool, and vegetable-tanned leather—backed by a lifetime warranty against manufacturing defects.

    Size Head Circumference (inches) Head Circumference (cm) Fitted Hat Size Equivalent
    XL 23.5 – 24" 60 – 61 cm 7 1/2 – 7 5/8
    XXL 24 – 24.75" 61 – 63 cm 7 5/8 – 7 7/8
    XXXL 24.75 – 25.6" 63 – 65 cm 7 7/8 – 8 1/8

    Frequently Asked Questions: Big Sized Hats

    Head circumferences above 23.375 inches (59.4cm) are generally considered large. The average men's head size is 23.25 inches (59cm / size 7 3/8), and the average women's head size is 22.375 inches (57cm / size 7 1/4). One-size-fits-most hats typically accommodate up to 23 inches, which means anyone wearing size 7 1/2 (23.5") or larger struggles to find comfortable fits in standard retail hats.

    Our big-sized collection includes hats in Small through XXXL. Size XXL fits 24-24.75 inches (61-63cm), and XXXL fits up to 25.6 inches (65cm). Most styles offer five to six size options (S, M, L, XL, XXL), with select styles available in XXXL. Many hats include adjustable drawstrings or sizing foam for fine-tuning the fit.

    Mass-produced hats are made for average head sizes, which leads to common fit issues:

    • Shallow crown depth → hat sits too high on the head
    • Tight circumference → pressure on temples and forehead
    • No adjustability → poor personalized fit

    People with larger heads often experience:

    • Red marks on the skin
    • Headaches from tight fit
    • Hats blowing off easily due to improper seating

    Big-sized hats address these problems by offering:

    • Deeper crowns (about 0.5–1 inch extra depth)
    • Wider circumferences for comfort
    • Adjustable sizing systems for a better fit

    XXL fits head circumferences of 24-24.75 inches (61-63cm), equivalent to fitted hat sizes 7 5/8 to 7 7/8. XXXL fits 24.75-25.6 inches (63-65cm), equivalent to sizes 7 7/8 to 8 1/8. If you measure between sizes, choose the larger size—it's easier to tighten a slightly loose hat with sizing foam or drawstrings than to stretch a too-small hat.

    Styles with adjustable features perform best for larger heads: the Aussie Golf Soakable Mesh Hat (sizes S-XXXL) includes a drawstring sizing system and ventilated crown; the Airflow Lightweight Recycled Outdoor Hat (sizes S-XXL) uses elastic sweatband technology; leather styles like the Down Under Leather Hat (sizes S-XXL) naturally conform to head shape over time. Avoid styles labeled "One Size" unless they specify they accommodate larger sizes.

    Properly sized hats look more proportional than undersized hats. A hat that's too small sits high on the head and actually makes your head look larger. A correctly sized hat sits at the proper position (about 1/8 inch above the ears) and balances facial proportions. Conner designs big-sized hats with proportionally scaled brims and crowns—not just wider bands—so the overall silhouette remains balanced.

    Yes. Conner uses organic cotton (grown without synthetic pesticides), hemp (requires 50% less water than conventional cotton), recycled polyester made from post-consumer plastic bottles, cruelty-free Australian wool, and vegetable-tanned leather. The brand operates from a solar-powered warehouse and uses biodegradable packaging materials. Founded in 2014 by Will Conner, who learned hat-making from his father Bill Conner (founder of BC Hats in Byron Bay, Australia in 1969), the company emphasizes responsible production and sustainable material sourcing.

    Use a flexible measuring tape and wrap it around your head about 1/8 inch above your ears, across the mid-forehead where the hat will sit. Keep the tape snug but not tight. Note the measurement in inches or centimeters. If you measure 24 inches, you need XXL. If you measure 25 inches, you need XXXL. If you don't have a measuring tape, use a piece of string, mark where it meets, then measure the string with a ruler.

    Choose the larger size. Most Conner hats include adjustable features like drawstrings, elastic sweatbands, or sizing foam that allow you to tighten the fit. You can always make a slightly large hat smaller, but you cannot expand a hat that's too tight. Hats also conform to your head shape over time, especially leather and wool styles.

    Yes. Big-sized hats require additional crown depth to sit properly on larger heads. While standard hats typically have crown heights of 4-4.5 inches, Conner's big-sized styles feature crown depths of 4.5-5 inches, preventing the shallow, perched fit common in mass-market hats. This additional depth ensures the hat sits at the correct position and provides better stability.

    Conner offers free 30-day exchanges through their REDO program (USA only). All hats are covered by a lifetime warranty against defects in materials and workmanship. If your hat fails due to manufacturing defect or faulty materials, Conner will replace it. For fit issues, contact customer service at 833-727-1410 for exchange assistance.