[Mike]

Same as Of Troy, the inside layer of my hats are slightly larger.
I either plan and make that the color most likely to be worn out or make the hat a little smaller and block it out.

With me it's not so much the K vs P, it's the strand of yarn that goes on my back finger doesn't get bound up as tight as the first strand I wrap for my front finger.
Even when I do socks where both sides are Ks the inside one is looser.

Eric,
You don't say what the problem was. Yes it can be done.