MickeyEars, did you put the name side on the front or back of the shirt? I'm thinking about putting the name side of the hat on the back of the shirt, and the other side on the front. I wish I was good with applique', because I think it would be cute made out of something cloth with the name embroidered on the hat, then appliqued to the shirt. I get these crazy ideas, but I don't always get them to work.
The Bargain Town store where I live has sweatshirts (Russell, Hanes, etc. brands) for $3 for kids, and $4 for adults, so I'm not out too much money if I make a mistake or mess up too much!
Oh my goodness! I just had a thought about how cute it might be to somehow make a Santa hat to fit over the ears since this will be a Christmas trip! I'm going to look into that and see how it works.