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Just before I ordered my first Sunbody I read a review online that said this was indeed not good advice, and recommended ordering your normal size, soaking the new hat in water, and wearing it wet until it dried which would allow it to conform to your head. I've done that with both of my Sunbody hats, and it worked out for me....In my case, the "go up a size" advice was clearly wrong. I must be at the 7 end of 7-1/8, not the 7-1/4 end. (I haven't actually measured myself in ages, but all the 7-1/8 and 57 hats I've gotten in the last 20 years have fit well.) I should have gotten my usual 7-1/8, it would probably fit me perfectly even after the sweatband tightened up.
Hey, sizing when buying online is often a crapshoot. That's my only complaint. Otherwise, these hats are really great for the price.