The King having observed, that the hats of the several Regiments are of different sizes, and cocked in different methods, I am to acquaint you, that the patterns which are sent to the Comptrollers Office, for the Cavalry and Infantry, are, in conformity to the King's Orders, to be sealed by the Board, and deposited as patterns; and it is his Majesty's pleasure that the hats of the several Regiments are for the future to be made conformable to them, both as to the size of the brim and method of cocking. [4th February 1769. Miscellany Book: clothing correspondence. Adjutant-General to Mr. Fauquier. W.O. 30/13B.]
As the excerpt above shows, there is nothing new in the problem of trying to get a hat of the correct size. In my case the lack of uniformity all occurs within a single unit: the evidence is shown in the photos that follow.
I may go back at a later date and knock off a few of the worst hats and remodel them. But, for now, they are 'good enough' and I have a lot more urgent things to do if I am to be ready for the Christmas battle. Similarly, the unit's complement of officers and musicians will have to wait while other units are attended to.
The Le Nobles uniform does look aesthetically pleasing. I think I have made the light blue a little too bright (a touch of grey probably needed to be mixed in) but I am happy with the result this small error gives.