I don't know if anyone else has done this, but I did this for myself and figured if anyone else wants I'll share. Choices are a good thing.

These are skull caps (based on the original) but tweaked with essentially a new mesh that resides lower and covers the forehead.
I have 20 different color variations for now.

This is a Wipz for now. I still need to implement how they will be distributed throughout the game w/out mod conflicts. (I'm thinking of adding them to leveled lists and/or vendors lists by script)
(I'll see how that goes)

In the meantime here's a preview, enjoy.
http://www.fallout3nexus.com/downloads/file.php?id=11227

-Mush-

I'm not sure if this is what you mean by tweaked mesh but this is a skull cap:
http://www.skichalet.com/v/vspfiles/photos/1695056250014-2.jpg

I know, that's one variety. I'm not a modeler so I basically took the covered head bandanna edited the mesh in Nifscope to push it down in front of the forehead and added several textures.

My dad and his Harley pals call those bandanna's skull caps so I just picked up the name from them.

Anyhow, I'm currently testing to see if they got put in the game via the script I made. It's a bit difficult as there aren't many armor/clothing vendors. With a new character I'm finding it difficult to find them.
I also added them to several hat lists, but to get a specific hat to show up is extremely rare as it is.

Once they're in, I can release the mod.

-Mush-

Hmmm, I tested having npc's wear them. When I add the headwear to them in GECK they load fine in-game. If i add them (via companion option) they wear them, (their heads go bald), but it seems they don't get visually loaded all the time (Sometimes they do though). If i go back into a companions inventory, then just immediately leave, the hats show up. Any idea why this may be happening?

Do items have to be loaded by the game (out somewhere or on people etc, in the GECK first?) Right now, I have a test box in Moriarty's with all the hats inside.

Thanks,

-Mush-