I'm desperate to find small headgear that won't block my companion's faces or voices. The ones I see on the gtn are always consukar only. Any idea of for a recioe or vendor that sells them?

For light armor, the Social Vendor on Coruscant will sell you some headgear that might do the job. You need to be at Social I for it, if I recall correctly.

For Medium armor, Synthweaver and Armormech can produce orange headgear that can be worn by, iirc, level 19 or above characters.

Traditional Thermoweave is almost the same as the consular. It's looks like a headband.

Here is a list of all the craftable orange armor in the game.

http://dulfy.net/2012/05/28/list-of-craftable-orange-gear-for-synthweavers-and-armormech/

Edited June 28, 2012 by Owsley