Also, working on Indiana Jones Adventure I can totally understand their use of the Dorfmans (although I don't like it.
) It's a lot easier to have a dozen cheap hats on hand in case the one he's wearing in one "scene" gets shredded, burned, or otherwise destroyed. Having that happen to a custom hat or tending to the backups is just too cost effective as opposed to the hundreds of hats in the store. I'm sure that the ones used in the show are catalogued by a central location but of course if EVERY hat gets destroyed, the nearest one is just outside the theater! After all, the Dorfmans are the officially licensed hats and most guests don't know the difference sadly. It really makes sense here in California where there are hundreds of people who work the Indiana Jones ride and the hat is a part of their outfit. The hats are all assigned out cast member by cast member, and locked up in a locker because they're an "expensive item." 
But those have already been worn and are just cleaned so most just buy their own hats to sweat into it themselves.All in all, if you think the stunt show costumes are bad, just look at the Indiana Jones Adventure figure costumes or the Tokyo meet and greet character!
