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    XXL Hats for Big Heads: Sizes 24 3/8"–25 1/8" (62–64 cm)

    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.

    Guides for choosing your hat

    Built Around Better Fit

    • Roomier proportions: These hats are designed with deeper crowns and wider circumferences for larger heads.
    • Material variety: Choose leather, cotton, hemp, recycled materials, organic cotton, raffia, or Australian wool, including non-mulesed wool options.
    • Useful construction: The range includes adjustable sizing systems, crushable designs, water-resistant materials, and outdoor-ready styles.
    • Family hatmaking: Bill Conner learned leatherwork in St. Augustine in 1969, moved to Australia in 1970, and made hats in Byron Bay for over 50 years.
    • Long-term support: Conner Hats offers a limited lifetime guarantee covering defects in materials and workmanship. The guarantee also includes a 50% off code to replace the same hat if yours is ever lost or stolen.
    Conner Hats Aussie Hats Aussie Wool Crusher Hat
    Boating or sailing hat with sun shield and chin cord

    Match Material To Use

    Start with the activity and finish you want. For rugged outback styling, compare the Bounty Hunter, Indy Jones, Down Under Leather, Lone Wolf, and Kangaroo Crossing. If you want a lighter outdoor option, consider the Airflow Lightweight Recycled Outdoor, Sunblocker Lightweight Recycled Outdoor, or Mountain Ventilated Packer Hat. The Tarpon Springs is a recycled floating sailing hat, while the Aussie Golf Soakable Mesh Hat suits wettable mesh construction. For natural fibers, look at the Black Creek Safari Hemp, Aussie Surf Organic Cotton, or an Australian wool style. Check each product listing for its available size, then compare your head circumference with the size information before ordering. If you are between sizes, review whether that style includes an adjustable system. Follow the care instructions for the specific material, especially for leather, wool, and water-resistant cotton.

    Size Head Circumference (inches) Head Circumference (cm) Fitted Hat Size Equivalent
    XL 23 1/2 – 24" 60 – 61 cm 7 1/2 – 7 5/8
    XXL 24 3/8 – 24 3/4" 62 – 63 cm 7 3/4 – 7 7/8
    XXXL 25 1/8" 64 cm 8

    Frequently Asked Questions: Big Sized Hats

    Hat sizing varies by brand. On the Conner Hats size chart, Large fits head circumferences of 22 3/4–23 1/4 inches (58–59 cm), while X-Large fits 23 1/2–24 inches (60–61 cm). A head circumference of 23 1/2 inches or more, typically hat size 7 1/2 and up, is considered large for hats.

    Our big-sized collection includes hats in Small through XXX-Large. XX-Large fits head sizes 24 3/8-24 3/4 inches (62-63 cm), and XXX-Large fits a head size of 25 1/8 inches (64 cm).

    Standard hats may not fit larger heads because their circumference can feel too tight, or their crown depth may not suit the wearer. This can make a hat feel uncomfortable or sit too high. Big-sized hats are available in larger sizes; check each product's sizing and fit details to find the right option.

    XXL fits head circumferences of 24 3/8-24 3/4 inches (62-63 cm) and corresponds to fitted hat sizes 7 3/4-7 7/8. XXXL fits a 25 1/8-inch head circumference (64 cm) and corresponds to fitted hat size 8.

    This collection includes hats in sizes XXL to XXXL. Check the size options on each product page to see which styles are available in your size.

    Properly sized hats generally look more proportional than undersized hats. A hat that's too small can sit high on the head and make your head look larger.

    Yes. Hats in this collection use organic cotton, hemp, recycled polyester made from recycled plastic bottles, Australian wool, genuine leather, organic raffia, canvas, weathered cotton, waxed cotton, and faux suede. The brand runs its original St. Augustine warehouse on 100% solar power (orders now ship from American Fork, Utah) and uses biodegradable packaging materials. We still maintain our company food forest at the site and have created a hub there for other small businesses to use the location. Founded by Will Conner, who learned hat-making from his father Bill Conner (founder of BC Hats, who has made hats in Byron Bay, Australia, for over 50 years), 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, then use the two free size inserts included with every order to fine-tune the fit.

    Some big-sized styles have crown depths of 4.5–5 inches. Crown depth can vary by style.

    If your hat doesn't fit, you can request an exchange within 90 days of purchase. The hat must be unworn and unwashed, have its paper tags attached, and be returned in its original packaging. If you chose ReDo at checkout, exchanges have free shipping; otherwise, return shipping is charged. Returns for refunds are subject to a shipping fee, and using your own return label incurs a $10 restocking fee. Items on the 40% Sale page are final sale and cannot be returned or exchanged. For help, email customerservice@connerhats.com.

    Several listings identify features useful for outdoor wear, including the Bounty Hunter and Indy Jones water-resistant cotton hats, the Dusty Road water-resistant cotton hat, the Murchasin River water-resistant boating hat, and the Tarpon Springs recycled floating sailing hat. Review each product description for its specific construction and care guidance.

    Care depends on the material and construction. Follow the instructions on the individual product page, particularly for leather, Australian wool, water-resistant cotton, hemp, and mesh. Avoid applying a general cleaning method to every hat; the correct approach can differ between a crushable leather style, a wool hat, and an outdoor fabric design.