This was a custom order for someone on Etsy but I made two because I liked it so much I wanted to list one in my shop.
I used pom poms on the end of his horns because I was pretty sure that if I sewed yellow balls they would cause the horns to bend. I like the pom poms, they look like they could be storing electricity to me.
I sell everything online on Etsy and/or Storenvy. I do sell to cons but not that many. The next con I have planned is Sakura-con but there are a few others I will be trying to attend.
Well, I am working on more Gengar hats but I am guessing you mean new design. It really depends on what you mean by soon. Soon as in before Christmas? Unfortunately no. But I so have several designs that I hope to get around to making after the holiday rush. Though I always put custom orders first so I never know exactly when I will make what.