ROFL, this is hilarious... As for suggestions for hats, ever think of stuff like,
Robin hood had
Darth vadar helmet.
Flower head hat. (
http://www.sshs57.com/photos/JPEGS/0...omicCon-67.jpg )
Graduation cap.
Micky mouse.
Santa cap.
Football helmet.
Cowboy hat.
Beer hat.
Doorag.
The "ghost" hat is a little to far, but not my problem.
Of course you don't need to make all these, just suggestions.