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Just noticed this on my Sniper. Just remove the hat from all your loadouts with quickswitch (you can bind this in options) and then press 6 to choose hats.

You need to remove it from all 4 loadouts. After that you can customize your loadout freely as long as you don’t choose the hatless hat again.

Doesn’t matter if you have a custom HUD or not.

I’m assuming it affects all the hatless hats.

E: Reddit is confused so i’ll just add this in here too. This is an additional problem that’s not caused by HUDs but the crashing due to HUDs still exists too.

E: Other players in reddit have confirmed the glitch.

E: Reddit posts:
http://www.reddit.com/r/tf2/comments/1fsord/psa_hatless_hats_crash_your_game_if_you_visit_the/
http://www.reddit.com/r/truetf2/comments/1fsnkn/psa_hatless_hats_crash_your_if_you_visit_the/

Valve has now fixed this.