All has become clear. In a flash of understanding and chagrin late last night as I looked at the pattern again after pausing on the second hat to contemplate the gauge and the too-loose weave of the fabric, I realized that my fatal mistake was in reading the yarn requirements line and assuming that Dale Hauk is a sport weight yarn. It doesn't really say. It calls for Dale Hauk and some sport weight yarn for the lining. Gven the gauge and the use of size 3's, my brain just read it all, lumped it together, and thought it all made sense for a sport or DK. Mistakenly assuming the hat was sport was where I got totally off track with hat #1. It all makes sense now. I'm frustrated, but at least I understand now why I ran into such sizing problems when no one else seemed to! It's back to the stash bins. But, I am sure I have similar colors - even more chocies - in worsted than I did when thinking I needed something lighter weight. Yes, I realize it was a very dumb mistake. I paid for it though. Wow.
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