I dont know where you live but I know my friends brother in law in Lakewood get their hats at a second hand store for I think 5-10 dollars and the hats are in good condition. Just ask people where you live if there is a second hand store they might have hats.
Brooklyn I dont know where to go but in Monsey you could try the metzias place on grove st. I couldnt find the phone number but anyone in Monsey will know where it is. They dont always have what you need but it might be worth trying.
most hat stores have cheaper lines of hats. Yaacov, if you still need help I am willing to pay part of the hat, Mods. please give yaacov my email address if he requests it. thanx