After a few experiments, I’ve settled on the final pattern for the herringbone rib ear flap hat. I’ve adjusted the decreases to keep the integrity of the pattern throughout the crown.

Its now available on Esty fpr $2.50:
http://www.etsy.com/listing/97181608/herringbone-rib-aviator-hat-pattern

Also available on Craftsy for the same price:
http://www.craftsy.com/pattern/knitting/Accessory/Herringbone-Rib-Aviator-Hat/12896