I realized that in my eagerness to give it to him, I had failed to block it. I knew I could fix it for him. I soaked his hat in warm water for about a half hour. When I pulled it out of the water, I formed it around an inflated balloon. This blocking technique worked perfectly. He tried it on today and it fits - covers his ears, is smooth on his head and looks good too. I only wish I had paid more attention to the stripes as they are a bit wavy in one spot. He doesn't seem to mind. At least now he is willing to wear it, which is a good thing.