I have a small feeling there's something weird with the no hats setting. Yesterday, a demo I was playing with kept losing his hat even though I have all hats enabled (and I was able to see my own, as well as others). It was an unusual riot hat with nuts and bolts, for reference.
The other weird thing was that for loadouts, melee's were MOSTLY gone, but not all. I was playing medic and I was stuck with the bonesaw even though I had the ubersaw equipped. I didn't get to experiment and find all the exact details (because I think some melee weapons were okay), but it was very odd, for sure.
Thanks for all the work you've put in. I said it in an earlier post but it's nice. :)