I'm not sure why I hadn't tried this earlier, but now it seems obvious.
On a whim, I decided to cut up a length of wire hanger and shaped it to my head. Then I stuck it under the sweatband. Voila, instant perfect fit for my not too ovalish head.
Has anyone ever tried this?
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How does it feel and why did you need to do this?
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It's not too uncomfortable, but I guess that depends on how you shape it. I suppose you could also cover the wire hanger too, but I didn't find it that necessary. I had a couple of beaters that were over sized, so I wanted to find a more stable way of making it fit than stuffing the sweat with paper towels. My head's also not too ovalish, so it's harder for me to get the "turn" without a little bit of trickery.