Hi Rob,
I don't think it's the brim which is giving the illusion of the hat being too big. It's the actual volume of the crown itself. Since the hat you're using is designed for a head with a larger circumference, it's always going to look too big for the face in my opinion.
Chris
Ok now you've got me spinning... I do see the excess size (as I alluded to earlier), but am just not certain which way to go - swap it or keep it.
Before I go further, let me state I have well enough experience in this hobby to know "how thing's work". I know that only I can make the decision. I know that little details like this add up to the greater whole. I know that once pointed out, things like this can bug you for a lifetime.
Now on to more objective observations...
--My hat is a 60, or 7 1/2 inches.
--Chris advises it should be a 58, or 7 1/4 inches
--Based on how the hat sits on the head, plus the fact that I will be adding hair, I'd be concerned with going to a 58, or a full 1/4 smaller
--I could go with a 59, or 7 3/8
But how much volumetric difference would there be between a 7 1/2 and a 7 3/8? Or even between a 7 1/2 and a 7 1/4? Would reducing the hat circumference size by just 1/8 or 1/4 inch really make the crown that much smaller that it would be noticeable?
Also, isn't the height of the crown more or less fixed a 5 1/2 inches, regardless of size?
Oh, what to do, what to do...
EDIT: I just remembered that the "7 1/2" or "7 3/8" doesn't directly translate to inches.