Yay! Hats work up pretty quickly, especially ones that don't have a lot of fancy schmancy. Even as slow as I am I can usually knock one out in a day (or two).
And your acrylic should be reasonably soft and warm, with the added benefit of being nigh on indestructible. I'm convinced that after the nuclear holocaust, the only things remaining on earth will be cockroaches and acrylic yarn. And possibly Funyuns.
As long as your husband doesn't have to deal with intense heat (and let's hope as a local truck driver, he doesn't), acrylic should be fine. It's not as warm as wool, but it's still pretty warm.
Knitpicks.com has some nice superwash wool that's really soft. I'm not sure they have it in bulky, but I know they have worsted, and it's really good for hats.
And mojo, the acrylic yarn might survive a nuclear holocaust, but it would probably all be melted into blobs, doncha think?