If you are between western hat sizes, choose the larger size and adjust it with a hat-sizing strip or professional fitting. A western hat should feel secure without squeezing your forehead, temples, or the sides of your head.
Start With an Accurate Measurement
Before deciding between two sizes, measure your head again. Use a soft measuring tape and place it around the widest part of your head, approximately one inch above your eyebrows and across the tops of your ears. Keep the tape level and comfortably snug, but do not pull it tight. Take the measurement two or three times and record the result in inches or centimeters.
Hat sizing can vary slightly between manufacturers, materials, and crown shapes. Your measurement is an important starting point, but the final decision should come from how the hat actually feels when worn. Try it on for several minutes rather than judging the fit immediately after putting it on.
Choose the Larger Size When in Doubt
If your measurement falls directly between two available sizes, the larger size is usually the safer choice. A hat that is slightly roomy can be adjusted, while a hat that is too small may create pressure points, headaches, or a visible mark on your forehead. Felt and straw hats can also feel different as temperature and humidity change, so a little extra comfort is useful.
The larger hat should rest evenly around your head without wobbling when you move. It should sit above your ears and remain stable when you turn your head. If it drops over your eyebrows, shifts easily, or feels loose in the crown, it needs more than a simple size preference—it needs a proper adjustment.
Always try a western hat on with your usual hairstyle. Hair thickness, braids, ponytails, and even seasonal changes can affect fit. Bring the hat band or hairstyle you normally wear when visiting Jim’s for a fitting.
Use a Hat-Sizing Strip for a Small Gap
When the larger size is only slightly loose, a self-adhesive hat-sizing strip can provide a comfortable, nearly invisible adjustment. The strip is placed inside the sweatband, usually along the front, sides, or back where additional security is needed. Add small sections gradually instead of using too much material at once. This allows you to create an even fit without distorting the hat.
Sizing strips work best for a minor difference. They are not a substitute for moving several sizes up or down, and they should not cause the sweatband to press painfully against your skin. If you need a substantial adjustment, professional reshaping or a different hat size and crown may be more appropriate.
Check the Crown and Shape
Two hats marked with the same size may feel different because their crown shapes and sweatbands are not identical. A taller or more open crown may provide more room, while a lower crown can feel snug even when the circumference is correct. The shape of your head matters as well; some people have a more oval profile, while others are rounder.
"I was exactly between two sizes and kept trying to force myself into the smaller hat. Jim’s helped me choose the larger size and added a sizing strip. It stays put all day and no longer gives me a headache."
— Marisol Herrera, Pacoima, CA
When to Get a Professional Fitting
If the hat rocks from side to side, leaves pressure marks, or feels loose even after a sizing strip, visit a western hat specialist. At Jim’s Western Wear in San Fernando, our team can compare sizes, evaluate the crown and sweatband, and help you select a comfortable fit for everyday wear, work, or special events. The right hat should feel natural from the first try-on—not something you have to constantly reposition.