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You could go to the dollar store. They have many hats you could choose from to match the colors without necessarily being exactly baseball or Star Wars.
Have him wear his own baseball cap and take some paper and make little "8's" and scotch tape them all over. Make them in his favorite color or your theme. Being Star Wars theme black or silver would show up nicely on any color of cap. I made my son a "I'm a eight today" t-shirt. We went to Six Flags that birthday and everyone wished him Happy Birthday all day wherever we were. He loved every minute. Making it all about them makes their day all the more special at any age! Have his guests wear their hats too! He will stand out with all the "8's" I hope you get the idea. Enjoy his special day! Jennifer :)
Why not let each child make his or her own hat? Prior to the party, make a circle out of either a card stock or oaktag type of paper and make a single cut to the center and adjust to proper size, cutting the excess amount (wedge) out. After determining the proper size template, cut one for each child attending. Before taping or stapling to get the cone shape, let each child decorate their own hat, by using crayons, markers, stickers, etc. After decorating, tape each paper to form the cone shape hat. For the chin strap, either use a thin string like elastic (found in sewing or craft stores) or a thin string or ribbon. Keeping seam in the back, attach strap to both sides of hat, just in front of the ears by making a small hole to tie strap through.
You could ask all the kids invited to wear baseball caps. You might be able to get some extras for free (for the kids who forget or don't have one) on the Freecycle in your area. Good luck!
why not just have him where his favorite teams baseball hat. then he can where it all summer.
A circle with a cut 1/2 way through to the center, pull the edges over on themselves, to make cone shape, trim edges to straighten base. Double stick scotch tape works great.