I'm rethinking the fabric a bit...perhaps a good choice would be ponte de roma? That's the stuff that cheerleader uniforms are made from; it's a stable doubleknit.
FFC has some blue poly ponte de roma, so I think we'll be able to get as much as we need.
So, I'll ask a variation on the same question...has anyone sewn w/the FFC stuff? Will it be too stiff/heavy for baptismal robes? We probably need something a bit beefy if we want to reduce the cling-when-wet factor we now have.
I sent the link to the folks who asked me to make the robes and I'm keeping my eyes open for a 'free shipping' sale...40 yards comes with a pretty hefty shipping charge, if I remember rightly.
So, we'll see what happens next. ;)