If it fits tightly, cut out only 1/4" of material and try again. You
do not want it too big, but repeat this step if it is still too tight.
Continue until you get the fit you like.
Now, you have two halves to this hat: the brim assembly and the crown
assembly. Both of these halves should be right sides out. Line up the holes
and pin them together, being careful not to pin the crown down. Baste
the brim and crown assemblies together. If the crown buckles a little on
the sides (Figure 7,) 
when
you slip it into the hole in the brim, then you have to take in the seams
a little at each corner, without altering the height of the crown, until
it fits neither with buckling, nor with gaps from being too small (Figure
8.) You should be able to fit the crown into the hole, and completely conceal
the sawtooth edge of the hole. You will size the lining the same way, then
set it aside to topstitch in later. Once you have the fit right,
pin the crown in place and sew it onto the brim.
Take a moment to look at your sewing machine. Most machines have a "free
arm", which means that you can stick the bottom part of the sewing machine
into things like sleeves and pant legs, so you can sew them properly instead
of sewing them shut. Sometimes, there is a part of the machine that you
have to remove to get the "free arm" to work. Please do this now, because
you are going to sew the two halves of your hat together using the "free
arm"`of your machine.
Stick the "free arm" into the hole and sew along the final seam line,
1/2" from the inner edge. Also, zig-zag the edge between the seam and the
notches you cut out earlier, to keep the fabric from unraveling at the
seam. Fold the raw edge of the lining under 1/2" to finish the edge, and
sew the inner hat band (if you chose to use one) onto it. Then topstitch
the lining into the hat, concealing the raw edges of the hole and crown.
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