Here are the instructions for the Batman hat I designed for my superhero loving son. He has a big head so this I would consider a youth small. It is easy to adjust up or down in size in increments of four, to accomodate the double rib.
I need to add in a diagram to help explain the ear join better
Cascade 220 (Dark Blue, Gold, Black)
#7 circular needles
#7 double pointed needles
Cast on 96 stitches with dark blue and join in a round on double pointed needles (24 stitches per needle)
K2P2 rib for eight rows
Increase one stitch at the start of the neck row (will be used for seam later on); knit 3 rows in stockinette
Switch to circular needles, begin pattern rows in intarsia following chart (28 stitches wide). Center pattern by starting the gold on the 43 stitch, or center pattern on midwat point. Knit this section back and forth as a flat knit.
Once intarsia section is complete, transition back to working in the round on the DP needles, decreasing one stitch at the start of the next row by K2tog.
Continue knitting with dark blue until hat measures 7.5 inches (19 cm) from cast-on edge.
To finish the crown and form the ears you will use a combination of kitchener stitch across the crown and knitted cast off (three needle cast-off) at each end.
Transfer the last 24 stitches (from the fourth needle, stitches 77-98, starting from stitch 77) onto a straight needle and then transfer the stitches from the first needle (in order 1-24). Transfer the stitches from needles 2 and 3 with the needle point ending in the same directions the other needle for joining. You will end up with parallel needles ready for joining.
Do a knitted cast-off of the first 11 stitches (Using a third needle put the point through the first stitch on the parallel needles and knit one stitch, repeat by knitting through two stitches then pass the first stitch over the second to cast-off. Repeat for 10 more stitches)
Kitchener the center 26 stitches together.
Transfer the final 11 stitches onto double-pointed needles and working from the outside in, do a knitted cast-off.
To finish ears, fold the cast off section so it is perpendicular to the seam. Using a tapestry needle, sew through the cast off seam to join it to the outside edge of the hat body. (diagram to be added later)
Next sew the inside 4 knitted cast-off stitches to the adjacent top seam of the hat to secure ears upright. Repeat for other ear.
Sew up seam from intarsia section.
Weave ends in to finish.