I used a 4x6 cap. The instructions say to use the insert for the 4x6 value. I think my nominal post wasn't nominal enough. The insert is made of plastic and does not stretch over the frame. And in all honesty, you want it to be nice and cozy. The problem went away after some encouragement from 40 grit. The hat itself looks high quality. I really didn't care much about the manufacturer's advertising on MY cap, but that's the way the world is these days.
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