OK, the order is now "etched in stone", I have approved the thread colors, and set the logo size - logo will be about 3" wide.
I am going to try to get these shipped as cheaply as possible. Since it is an "unstructured" hat it may be possible to fold it up into a bubble-pak envelope. I will try this with one to make sure it doesn't get damaged or permanently deformed/creased. If the envelope doesn't work I'll have to come up with some boxes...