I think I have this mastered. I'm making the hats with hardened leather and putting a headband in them with a chinstrap so they stay on when you fight.
I'm bringing 3 or 4 to sell at chaos. I have dyes and a burner and will color it and put your symbols on it right there.
$100 dyed any of the colors I bring(green, red, black, brown. blue)
$20 extra to carve your symbols into it, within reason.
Thanks
FB