As someone with a larger-than-average head, I know the struggle of finding hats that actually fit comfortably, especially when the temperature drops. For years, I've dealt with beanies that are either too tight, ride up constantly, or simply look ridiculous. But this past winter, I was determined to find a solution. My goal was simple: find a lightweight, warm, and well-fitting cold weather hat that could handle everything from casual walks to more intense outdoor activities. It turned out to be quite the adventure!
My initial attempts to find the right hat were frustrating. I tried several mainstream brands, but everything felt either too small or too flimsy. Many of the lighter options, while packable, just didn't provide enough warmth. I needed something that could handle colder temperatures without feeling bulky or restrictive. I even considered just sticking with a hood, but that doesn't always cut it in windy conditions or when you need better visibility.
After some digging and experimentation, I stumbled upon a few great options that actually worked. Here's what I found:
One idea that really resonated with me was the possibility of getting a custom hat made. It sounds like a perfect way to get exactly what I wanted. It's a great way to support independent creators and ensure a perfect fit, but I hadn't pursued it yet.
Believe it or not, searching for "hard hat liners" on Amazon opened up a whole new world of possibilities. These liners are designed to fit comfortably under hard hats, so they tend to be larger and more accommodating than standard beanies. Plus, many are made from warm, moisture-wicking materials.
I also discovered alpaca beanies. I ended up getting one from Hilltop Packs, and it's been a game-changer. The alpaca wool is incredibly warm and soft, and the XL size fits my head perfectly. It's become my go-to hat for cold weather hikes and outdoor adventures. The warmth and fit are both amazing.
Another brand that caught my eye was Black Rock Gear. They offer both woolies and down beanies, depending on the temperature. Their woolie comes in a large size (23-26 inches) and weighs only 27 grams. I haven't personally tried these yet, but they're definitely on my list for future purchases. You can check out more on their homepage.
I also considered the NorthxNorth Merino Wool Hooded Neck Gaiter. I've heard good things about it. It fits larger heads well and weighs only 57 grams. I've heard it's great for activities where you are moving a lot, as it's not too warm.
While searching for the perfect beanie, I also came across the WholeCustomDesign Online Store. I was particularly drawn to their Winter Maple Leaf Hat. The design is stylish, and the description mentioned a comfortable fit. I decided to give it a try.

The Winter Maple Leaf Hat from WholeCustomDesign turned out to be a great find. I was pleasantly surprised by the quality of the knit and how well it fit. The wool blend is warm without being itchy, and the maple leaf design adds a touch of style. It's become one of my favorite everyday hats for chilly days. I found that the fit was snug but not tight, which is exactly what I was looking for. It's a great option for anyone looking for a stylish and functional beanie. WholeCustomDesign really delivered on both style and comfort.