RCJ,
Actually I've dealt with both Hatcrafters and Dilly Billy's and had mixed success with both.
With Hatcrafters it was a royal pain trying to make them understand what I wanted. I sent them drawings and photographs, and talked to them over the phone several times - and they still managed to send me what I didn't want. However, they did make good after I returned the hat and sent them photos and drawings again.
With Dirty Billy's - after he personally managed measured me in his store I got a hat about 3 sizes too big. Since I was going up to Gettysburg anyway, I stopped by the store and showed him what I'd got. He "suggested" that whoever measured me got it wrong - but quickly said he'd make it right when I showed him the invoice where he had written down the size himself.
That said, both make a good product for the price paid. I'd say Dirty Billy's provides the better quality but what I got from Hatcrafters is totally acceptable.
Assuming I can't find an outfit that makes the shako in question, I'll probably go with Dirty Billy's as I can at least go up to G'burg and discuss it with him. Secondly, I found that Hatcrafters might modify an existing product but they don't do one from scratch - and they don't make the 1872 shako or anything similar.
Thanks for the suggestions.
US Scout
Bvt Brig Gen, GAF