I've become a facebook 'fan' of Tilley Endurables, and one of the discussions lists precisely what to do:
For Canadian and International customers, please mail to:
Returns Department: Tilley Endurables
900 Don Mills Road
Toronto ON Canada
M3C 1V6
Score. So now I have to box up and mail The Hat.
They've offered to send back the hat if I want to keep it. On the one hand, it has been with me practically every day for 9 years. On the other hand, it's done.
I'll have to think about this a bit.