Thank you everyone!
Well, I found some denim like material in my stash leftover from years ago when I made curtains for the boys playroom. There was enough to make a tie and a matching hat. I lined the hat with terrycloth. The hat turned out a lot better than the tie. I bought the thinnest, softest interfacing I could find at Joanne's. The tie was still "thick". DH had a little trouble tieing it. But, he wore it to work along with his hat.
I'm thinking next time just line the tie like Buzzy Bee did.
Appreciate everyone's input.