Gil - The hats are turned green and then put upside down into a holder. Rubber bands are then stretched across to bend the sides up as the hat dries.
Chris - Yes they are full size. Chris measures your then goes through a procedure that I have forgotten to determine the size of the head opening. My wifes fits her great. Mine is a little tight front to back but it's still wearable. Check out Chris' website at www.knot-head.com Almost everything he makes is turned green, thin.