Pictures would help us out. Cannot really make a comment without seeing the issue. Off the shelf hats are made in a production line manner and maybe your hat(s) were made by the new guy. The reed area of the sweat should sit a bit proud of the brim break as you don't want that area hitting the forehead. Sometimes if the machine sewer is sloppy it can sit too far out. Post pictures for a better response.I have these off the shelf hats that someone looking at me could see the sweat band but other hats you can not. Does it matter?