XXL Hat Size Chart: Finding Your Correct Baseball Cap Size

For US baseball caps, XXL usually fits a head circumference of 23⅛–25 inches (58.7–63.5 cm), which matches fitted sizes 7⅜ through 8.

The range above comes from Flexfit’s published XXL cap chart, and New Era’s fitted chart labels those same measurements as sizes 7⅜ to 8 rather than “XXL” at all. Below is how to measure once, convert it correctly, and stop guessing.

How Do You Measure Your Head For A Baseball Cap?

Wrap a flexible tape around your head where the sweatband will actually sit — across the middle of the forehead, about ½ to 1 inch above the eyebrows and ears, around the widest part of the back of the skull. Keep the tape level and untwisted, snug but not tight, and measure twice; if the numbers disagree, use the larger one. No tape measure on hand? A piece of string marked at the meeting point and laid against a ruler works just as well.

Two measuring errors cause most bad purchases. A tape run at an angle or left loose reads oversized, which pushes you into a cap that swims. And skipping the re-measure hides the difference between a snug 23½ and a true 24.

XXL Hat Size Chart: Circumference And Fitted Equivalents

Match your measured circumference to the chart row below; the fitted size column is what you’ll see on New Era 59FIFTY and similar fitted caps, while XXL is the label Flexfit uses on its larger caps.

Flexfit’s Wooly Combed Cap in XXL covers that full 7⅜–8 span, with a listed crown height of 3½ inches. New Era’s chart runs the same distance through size 8 at 25 inches and explicitly applies to the 59FIFTY, Low Profile 59FIFTY, Split Panel 59FIFTY, 59FIFTY A-Frame, and Retro Crown 59FIFTY. The New Era sizing chart is the reference to check against the specific silhouette you’re buying.

Why Doesn’t XXL Mean The Same Thing Everywhere?

No universal US standard defines “XXL” for baseball caps — it’s a manufacturer or retailer designation, so the number behind it moves from brand to brand. Treat every product’s own chart as the authority, and never assume the XXL from one label equals the XXL from another.

• L/XL is not XXL. New Era uses L/XL across roughly 23⅞–25 inches on many 39THIRTY-style stretch caps, but that boundary shifts with the silhouette.
• Some caps skip XXL entirely. Flexfit’s Pro-Baseball On-Field Cap lists only S/M (6¾–7¼) and L/XL (7⅛–7⅝). The Premium Wool Blend runs S/M 6⅞–7¼ and L/XL 7¼–7⅝.
• Label centimeters aren’t your head. New Era warns that the centimeter figure printed on a cap label may not equal your head circumference.
• Construction changes fit. Crown shape, sweatband thickness, hair volume, and whether the cap is fitted, stretch-fit, or adjustable all shift comfort at the same measurement.

Should You Round Up Or Down Between Sizes?

Round up. New Era recommends sizing up when your measurement lands between two fitted sizes, and fitted caps have no rear closure to loosen — a slightly roomy cap beats a tight one every time.

Stretch-fit and adjustable caps can absorb a range, but a fitted cap can’t. Once you know your number, browsing the tested XXL baseball caps worth buying saves you from re-measuring against a dozen mismatched charts.