Mason, have you ever tried using 24" for hats? I use a 10-10.5 and CO around 70-80 sts. What I've been doing recently is use a larger one for the CO and join by knitting the first round on the smaller one. There's just a leeetle bit of a stretch the second round, but after you have another one or two, the circumference is large enough that the 24"s are just about right. What happens is the smaller circumference is in the center, but the outer rounds are a bit looser and it fits just fine. Then you have to fiddle with a ML or half a one, when you get less than 60 sts, but it makes knitting most of the hat easy.
Just something to try out if the 16"ers turn out to be too small for your hands.