Not to bump an old post, but after a ton of digging through old boxes of stuff from my childhood, I came across the very hat I spoke of in my original post. It's taken some love, but not in too shabby of shape 15ish years later. 
Heh... Just pulled out my old Aces High Hat ( and Shirt and mouse pad )
My hat looks just like your's except the bill is black, has a brass adjustable clamp on the back
My shirt and mouse pad has the original Aces High splash screen picture on them....
Back during Aces High through Aces High II, I ran a Cafe Press "premium" store, to where I could have as many different items as I could think of, and did special orders where squaddies could send me screen shots and I would put them on the back, with their handle on the front under or over our Damned squad patch.....
I of course asked and got permission from Dale(hitech) first, to use the Aces High Logo, etc....
Not sure how hitech ( and HTC) feel about it these days... Our Damned Gift Shop at cafe Press was open from like 2003/2004 up until 2010 until right after Jordi had finished up with the AirWarrior and Damned squad and friends reunion he hosted.....
I did a lot of one off designs back then for different people in the game some from other squads, some who didn't fly in squads....
Several other squads started creating their own stores several months+ after the word got out....
If I remember correctly I created and opened our store about a year and a half+ before HTC first offered merchandise
