Don't know if this will work for you, but
I use a silk balaclava in cold weather on the motorcycle. The stitching bothered me until I started wearing it inside out. Stitching, tag, etc. are now outside, inside is smooth and comfortable.
I realize a Nomex hood is different, but it may work.
Pretty simple / elegant / brilliant. Both my single layer Sparco and double layer Puma look to be better turned inside-out, but there are still seams to contend with. To make matters worse, Ross has a sensitive forehead / melon.
Last edited by Frank Amoroso; 06-19-2011 at 04:24 AM.