Great work with the Green Stuff Stuart.
Have you ever toyed with the GW 'Empire' heads? They are a whisker too large for the Perry plastics - but not so that you'd notice unless you were really looking to pick holes.
Mason kindly sent me a few, and I've used some of them - they include quite a wide selection of Tudor-ish / landsknecht style flat hats, with and without adornment... For instance:



Not sure how easy these are to get hold of, but I guess an appeal for spares here on LAF might yield a few donations to further youur project
