If i make his head square itll look like crap, or in your case worse than this
It's not just a case of squaring them down, that's half the battle. The other half is making it fit Blockland's theme. Here's an example.
Castle crashers yeah? Okay, they're round headed. Can it be converted to Blockland and stay round?
Yeah it can be put in blockland rounded, but it doesn't fit blockland's theme, like your hats.So try making them fit Blockland's theme a little, like this version.
Do you see where I'm getting at with making the hats more in theme to the game? I'm sure with enough time and effort you can make your own hat fit.
You can't make the hat worse by trying to make it fit into the theme.
And please, don't take me for someone who you think is just trying to politely say "Your anime sucks." This is criticism, not taking jabs.
EDIT: Forgot to add: Don't make the faces in a paint program, model them as well. The only hat that's worked with one part being a model, and the other being in a paint program is Toby. Hats like these don't make 'em work.