Once I got something better I jumped full size but I remember ending up with "cone head" hats for a while. I still wear #17... I consider that the "OG Black Rock Hat". I Made it on the original Blue Jeans Machine too which was free at the time.
That machine did HORRIBLE stitching and was simply a dog to use, but I think I built out and sold nearly 300 hats before being able to upgrade. Now I'm numerous machines down the line and hundreds more hats finished. It's always changing though. I've tweaked the pattern, sizing and every other little thing on the hat for years, so at this point I run versioning on the hat. Starting with that 17th hat as version 1.0 I'm now up to version 4.0 with about 15 minor revs to that pattern and assembly. I figure I've got to keep pushing the design forward all the time. Hoping for version 5.0 sometime next year if I can upgrade to a dream piece of equipment.
I also up revisions with new tools and jigs too, so at this point I've got a shop full of jigs, markers, tracing tools, clamp setups and a full on machine I built to help stuff these things. It's the engineer in me
I like the differential cut you're using, nice work. Next up I wanna see one with differential cut 3D baffles with side block or offset baffles. I've got one prototype with a full side block and offset baffle construction using noseeum netting. Pain to make but looks kinda like your rocket beanie for size, just no sewn through baffles. I'm gonna use some of that design in another item I've been working on for a year or so. Won't be a beanie though, but it will go on your head... Sometime in 2012 assuming we get out everything we want to this year.
Black Rock Gear
Hope this makes sense and thanks,