Take a look at Sterkowski. They have a very large range of all sorts of amazing caps and hats, all hand-made in Poland at great prices. Their materials and craftsmanship are top notch.
I would also suggest you look at Hat People caps. Their selection of materials is somewhat limited and they don't provide snaps to secure the front of the "crown" to the brim, but they do have four different "cuts" (i.e., the size/volume of the top of the cap) to choose from and they make each cap to the measurement(s) you provide. I have three of their caps, and they'd be the first place I'd look if I wanted a fourth.
While I really like my custom Cordova caps, Hanna hats are a great place to start and a very good value. Lots of colors and several styles and often available (new or used) on ebay.
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