I'm still not getting the way it's filtering stuff though.
Searching "men's hats" -> Showing 1 - 24 of 12319 Results
Click "Special Sizes" -> Showing 1 - 24 of 12319 Results
Click "Big and Tall (10)" -> Showing 10 Results
Of those 10 results, 6 are shirts, 1 is a fleece stocking cap, 1 is a fleece ballcap, and 1 is a "trucker's cap".
On the other hand, if I go to say [link|http://www.cabelas.com/cabelas/en/common/search/search-results1.jsp?Ntk=Products&QueryText=men%27s+hats&_D%3AhasJS=+&Go.y=0&Nty=1&hasJS=true&No=0&Ntt=men%27s+hats&noImage=0&Ntx=matchall&N=4887&_DARGS=%2Fcabelas%2Fen%2Fcommon%2Fsearch%2Fsearch-box.jsp.22&Go.x=0|Cabelas] and search for "men's hats" I get 4 pages, 71 items and they're all hats. If I go to [link|http://www.llbean.com/webapp/wcs/stores/search?langId=-1&searchTerms=men%27s+hats&startRec=1&numWanted=5000&loggedIn=0&page_type=null&hotBG=0|LL Bean] I get 3 groupings of results of 38 total items, the vast majority of them being - wait for it - men's hats.
I don't think the UI is the major problem with your new toy. I think the logic behind it needs to be cleaned up substantially. If I have entered a fairly restrictive search like "men's hats", I don't want to look through T shirts or 12,319 items to find what I'm looking for. It's great to be able to drill down in "men's hats" to find hats that fit a big head. But a T-shirt isn't a hat. Categories that don't work right are going to frustrate your users and have them go somewhere else.
Don't try to be more clever than your users.
HTH.
Cheers,
Scott.