Ambulo tua ambulo.
Cut 5 of these out of fleece (fabric stretch should go across the short side of each panel) and sew them together. You might have to put a few hand stiches in at the top to close it completely. This will be your liner.
Now, make a pattern that is exactly like the liner panel pattern, but 1/4" to 1/2" bigger all around. Cut 10 of these out of your shell material (I used 1.9oz black ripstop nylon). The "wrong side" could probably be made of can be of some cheaper downproof taffeta. Sew these together in pairs, leaving the bottoms open. Mark your quilt lines (fold in half and draw a vertical line where the crease is), then draw horizontal lines at 3" and 6" from the bottom. Remember that the side you draw on will be on the inside of the hat! Fill each panel with down to your liking and sew the bottoms shut. Sew the quilt lines as marked. Sew all the panels together (wrong/marked-on side out).
The flap is made by cutting a strip of fleece long enough wrap around the neck and cover both ears, twice as wide as needed. Fold in half, sew up the open edges (except for a small gap), trim the edges, then flip inside out through the gap.
Pin the liner inside the shell right-sides facing eachother, with the ear flap pinned between them (facing toward the inside, not hanging out). Sew the liner and shell together. This might be a little difficult when sewing through the flap...
Rip a few threads out of one of the seams between the panels of your liner, invert the hat through the hole, hand stich the hole closed and you're done!
The size is a snug L.
sort of like a Russian tank commander.
Not all who wander are lost.
Very nice. Your shaved head must be enamored like the rest of us!
looks like you put some time into fit and finish. Very impressed.