i am sooo glad you posted this. my brother is 6'3" and has a head slightly smaller than my dad's which is 24 5/8". i can't measure my brother's head because he's on okinawa. i got 7" into this hat when i discovered that my dad couldn't even get it on his head! i've been trying to decide what to do. i've almost settled on hot head from one of the s 'n b books, but i'll want to add 4/8 sts to make sure it's big enough. i never thought it would be this hard to knit him a simple hat! :roll:
i'm definitely watching this thread.
eta: so yet again i've remembered wrong. my dad's is 23 3/4", which means my brother is probably 23 1/2". i just found this new pattern on ravelry. (non-ravelry link) it was originally knit for a 23" head on sz 7s. would going up to 8s make much of a difference? i think i may swatch it to see. i'm using KPs swish worsted, and i'm discovering it's not as heavy as most worsteds i've used. i don't really have that much time to play around with it, so i'd better get started. i'm sure you could knit it longer (a lot longer) so you could fold it over the ears. i still have to decide if i want to knit it longer. i'm thinking i may not have time now.
eta (again): i just found this one that says it fits a 20-24" head. i actually think my brother will like the ribbing on this one more. the pattern calls for sz 6. i'll go up to a 7 or 8 just to be safe. i'll swatch first, then decide. i know i've spent way more planning this thing than i will actually it, but it's totally worth it. my brother's amazing.