Your over-sized melon has been kept in mind. (we have the same hat/head size) I will have a cap size to fit you. Unfortunately the last style I used shrunk in production size so it'll have to be something else. But that's the plus to working with these patches. Besides looking better I don't have to mess with embroidery color variations, which equates to being able to carry quite a few different colors and styles to suite others needs and preferences.