Why did they change this hat to cheaper material with a soft forehead and how can I get the older style?

That's the style. "Dad cap" relax panel fit. I look ridiculous in flat bill trucker caps... I'm also a dad so there's that.

I have big ol head (7 5/8 hat) + long hair for a dude, 1) would this hat fit 2) Does it have that awkward hump in front a lot trucker Hats have ??

Yes they have a weird spot in the front in the middle. Wash it and dry it stretched over something that pushes that spot out and let dry. I wear a 7 5/8 and have three snaps together and it’s perfect.

Does this hat have a plastic or cardboard brim?

This hat has an interior plastic brim.

Are these baseball caps, real baseball cappy like?

IT'S FAIR... NOT OVERLY CRAZY ABOUT IT... KIND'A HIGH TOP

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