OK. I have good news and bad news and then more good news.
Good news is that the structured hats, putty hats and one khaki hat are done and on their way to me.
Bad news is that the other hats aren't yet on there way due to yet another embroidery mistake.
Which leads me to the other good news...
The embroiderer has reordered the affected hats and has agreed to send the originals as well. So anyone with an affected hat can get an extra free (actually for the extra shipping if significant).

The extras will not have custom names on them.
The mistake was minor - while stitching the BYOAC side, the straps were stitched into place. This means those hats can be adjusted smaller but not larger without cutting the strap to release it. According to the embroiderer this won't affect the majority of people (only "extreme large" has been... errrr... disabled.)