I could never order a New Era online. I tried on two Nats hats (the ASG hat and a Cooperstown one) in 7 1/8 and had to go up in size on one and down another. QA/QC is not something they believe in.
Yep, and now that Fanatics is running Shop MLB the return policy is even worse than before. Now I just buy at the stadium if I really want a new hat and pay the premium so I don't have to deal with returns or going to Lids. Even the New Era fitted hats that are Made in the USA (which used to have really good QA/QC) have went to crap in terms of not only fit but also the stitching.
To be completely honest, I've actually pretty much abandoned New Era fitted hats for Ebbets Field Flannels (
http://www.ebbets.com/). For $10 more I get a much better produced hat that consistently fits, has some really cool rare logos, and gets me tons of compliments. My wife got me this one for my birthday and everyone from our vet to strangers on the street want one: