Comeaux Caps Size Chart and Sizing Guide: How to Measure and Find Your Fit

← All Posts gear apparel Weld Gear Team Last updated on July 19, 2026

The first Comeaux cap most welders buy is the wrong size. Not by a lot - usually half a size off - but enough that it bunches under the helmet on the first long shift and gets shoved in a drawer. The problem isn’t the cap. It’s that most people order their baseball cap size and don’t realize welding cap sizing works differently.

Comeaux Caps are sized by hat size, which corresponds directly to your measured head circumference. Your baseball cap size is usually a general S/M/L or a fitted size measured at a slightly different reference point. The two don’t reliably correspond. Measure your head before ordering. Here’s how to do it, what the numbers mean, and what to do if you’re between sizes.

How to Measure Your Head for a Comeaux Cap

You need a soft fabric tape measure. A metal tape measure works in a pinch if you also have a piece of string to hold the measurement.

Stand in front of a mirror or have someone help you.
Place the end of the tape measure at the center of your forehead, about one inch above your eyebrows - roughly where you want the front of the cap to rest.
Wrap the tape measure around your head, keeping it level: above your ears, across the back of your head at the nape of your neck, and back to the start point.
Keep the tape snug but not tight. It should sit where you want the cap band to rest, not pulled down hard.
Read the measurement in inches. This is your head circumference.

Measure twice. Head circumference measurements can vary by 1/8 to 1/4 inch depending on how you hold the tape. If your two measurements differ, use the average.

Comeaux Caps Size Chart

This size chart is based on Comeaux Caps’ published sizing guide and cross-referenced against retailer-provided data.

Hat Size	Head Circumference (inches)
6-1/2	20-1/2” to 20-5/8”
6-5/8	20-3/4” to 20-7/8”
6-3/4	21” to 21-1/8”
6-7/8	21-1/4” to 21-3/8”
7	21-3/4” to 22-1/8”
7-1/8	22-1/4” to 22-1/2”
7-1/4	22-5/8” to 22-7/8”
7-3/8	23” to 23-1/4”
7-1/2	23-3/8” to 23-5/8”
7-5/8	23-3/4” to 24”
7-3/4	24-1/8” to 24-3/8”
7-7/8	24-1/2” to 24-3/4”
8	24-7/8” to 25-1/8”

Comeaux Caps offers all of the above sizes in most standard styles. Less common sizes (6-1/2, 6-5/8, 7-7/8, 8) may have limited availability in specific prints at any given time. Solid color caps tend to be consistently stocked across the full size range.

What If You’re Between Sizes?

If your measured head circumference falls at the top of one size range or the bottom of the next, go up a size. A cap that’s slightly large will conform and settle as you wear it; a cap that’s slightly small will tighten over a shift and cause discomfort. Cotton fabric has minor stretch over time but won’t loosen enough to fix a cap that’s a full size too small.

The exception: if you’re between sizes and you know you’ll be wearing the cap under a tight-fitting welding helmet shell, the slightly larger cap may feel fine on its own but bunch uncomfortably under helmet pressure. In that case, try the smaller size first in-helmet before committing.

Short Crown vs. Long Crown (Deep Crown)

Comeaux makes both medium crown and deep crown styles. This is the vertical distance from the band to the top of the cap.

Medium crown (standard): The 2000R reversible series and most standard styles use a medium crown. This is the classic welding cap profile - enough height to clear the top of your head comfortably without adding excessive bulk inside the helmet.

Deep crown (1000/1000E series): The single-sided deep crown cap sits higher on your head. Some welders with longer hair prefer the deep crown for the additional clearance. Others find it feels like too much fabric inside the helmet. If you’ve never tried a welding cap before, start with the standard medium crown.

Crown height is independent of your hat size measurement. Your head circumference determines the size; your personal preference and hair length determine the crown height.

Does Baseball Cap Size Match Comeaux Size?

No - not reliably. Baseball caps are often measured at a different circumference reference point, and fitted baseball caps use a slightly different measurement method than welding caps. A person who wears a fitted baseball cap in size 7-3/8 might actually measure at 7-1/4 or 7-1/2 in Comeaux sizing. Always measure rather than assuming.

Comeaux’s own guidance on their site specifically notes this: your welding cap size is not the same as your baseball cap size. Measure fresh each time, especially if you’re ordering a new style from a different production run.

Verified Amazon Listings for Comeaux Caps

Comeaux Caps are available directly on Amazon in solid colors across multiple sizes. Solid color caps are the most consistently stocked and easiest to size-order without worrying about print availability.

Shop Comeaux Caps Solid Black (Size 7-1/2) on Amazon

Shop Comeaux Caps Solid Black (Size 7-3/8) on Amazon

For printed and reversible styles, Comeaux Caps’ own website (comeauxcaps.com) carries the full range of prints in all sizes. Amazon availability for specific prints varies by season and production run.

Common Sizing Mistakes and How to Avoid Them

Using hat size from a baseball cap: As noted above, these don’t correspond directly. Measure fresh.

Measuring too tight: Pulling the tape measure snug against the skin gives a slightly smaller reading than the actual internal cap circumference needs. Keep the tape at the same tension a comfortable cap band would exert - snug but not compressed.

Measuring over thick hair: If you have significant hair volume where the cap band will rest, measure with your hair down and styled as it would be when you’re wearing the cap. A measurement taken with hair pinned flat will size too small.

Ordering by feel from a worn-out cap: Old caps stretch. A cap that fit size 7-1/4 when new may feel like a 7-3/8 after a year of use. When ordering a replacement, measure again rather than reordering the same size by memory.

FAQ

How do I measure my head for a Comeaux cap? Wrap a soft tape measure around your head at the point where you want the cap band to rest - about one inch above the eyebrows at the front, above the ears on the sides, and across the nape at the back. Read the circumference in inches and match it to the size chart above.

What sizes does Comeaux offer? Comeaux caps range from size 6-1/2 through size 8 in fractional increments: 6-1/2, 6-5/8, 6-3/4, 6-7/8, 7, 7-1/8, 7-1/4, 7-3/8, 7-1/2, 7-5/8, 7-3/4, 7-7/8, and 8. Most styles stock the full range; less common sizes like 6-1/2 and 8 may have limited print availability.

What if I am between sizes? Go up a half size. A cap that’s slightly large settles and conforms with wear. A cap that’s slightly small tightens over a long shift. The exception is if you’ll be wearing the cap under a tight helmet shell - test the fit in-helmet before committing to the larger size.

What is the difference between medium crown and deep crown? Medium crown is the standard Comeaux profile - fits most welders comfortably inside a helmet. Deep crown sits higher on the head and provides more clearance for welders with longer hair or high head shapes. Crown height is a preference choice, independent of your hat size.

Does cotton shrink after washing? Cotton can shrink slightly in the dryer, particularly on the first wash. If your cap is at the smaller end of your size range, wash cold and air dry to minimize shrinkage. If you’re comfortably mid-range in your size, machine wash and tumble dry low is fine.

Can I return a Comeaux cap if it doesn’t fit? This depends on the retailer. On Amazon, standard return policies apply. Through comeauxcaps.com, Comeaux offers a satisfaction guarantee. Check the return policy before ordering, especially for printed styles where your size may not be immediately restockable.

What is the largest Comeaux cap size? Size 8, corresponding to a head circumference of approximately 24-7/8 to 25-1/8 inches. Welders with head circumferences above 25 inches should contact Comeaux directly - they have historically accommodated custom sizing requests.

Do Comeaux cap sizes run large or small? Comeaux sizing is accurate to their chart, but there is variation across print runs and cap styles. Single-sided caps (1000E) tend to run true to size. Reversible caps (2000R) have two layers and may feel slightly smaller inside due to the additional fabric at the crown. If you’re ordering reversible for the first time and are between sizes, order up.

References

Slug: comeaux-caps-size-chart-and-sizing-guide Excerpt: Comeaux Caps range from size 6-1/2 to 8, sized by head circumference. This guide shows you how to measure correctly, provides the full size chart, and explains what to do when you land between sizes - including why your baseball cap size won’t get you there.