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As a person who sews, I understand fabric, but I've never done anything like you are talking about. My advice will be thought out, but not experienced.

I don't think you will be able to make nice cuts with a rotary cutter. They work well for quilting weight cottons, slice beautifully and cleanly. But a Navajo blanket will be too thick, in my opinion.

I don't know what your budget is, but consider getting a tailor quality scissors. If you have a JoAnn Fabric, or Michael's Craft stores, they have nicer scissors. Look for a 50% off coupon.

Practice on the fabric on the edges before cutting your holes!

With a thick blanket fabric like a Navajo, consider also something stronger than Fray Check. Fray Check is a thin adhesive, similar to Super Glue.

Here is an adhesive that is thick, almost like liquid glue sticks, which you can put carefully around your openings, let it dry and it should stop the fray.

Adhesive: https://www.amazon.com/Beacon-Fabri-Tac-Permanent-Adhesive-4-Ounce/dp/B00178MNFO/ref=sr_1_1?ie=UTF8&qid=1479822135&sr=8-1&keywords=fabri+tac

Just wondering if some type of water and stain repellant would help in a couple of ways? If rain gets in, or if people's hands are dirty or oily when cranking the window, stain repellant may help keep the fabric clean looking. Maybe it would help with abrasion also? Here is a good one. Again, spray and let dry before cutting and inserting fabric:

http://nooga.com/166602/the-diy-designer-how-to-waterproof-and-repel-stains-on-fabric/

If you think of it, please post after pictures, this sounds really cool. I didn't know this was a thing.

Shibori is exactly what I was going to recommend. It's a lot of fun, and you can make a lot of the techniques look super chic.

I used to borrow this book from the library, natural dying is great for realising the connection we forge with the fabric and garment when dying it ourselves.

There’s some double knit fabrics, that have woven like structured faces and are wp, wr, and tpu inbetween and soft warm interiors. Just gotta hunt for them.


Although I think it would be best if u find something with fleece or shearling, instead of thermal for the inside. Most thermals are waffle knits, or rib knitting, that are not wp or wr.


https://www.amazon.com/Gash-Hao-Waterproof-Softshell-Snowboard/dp/B07R47JJW3

I would think you would want something like netting. Maybe even Fish Netting. That way if the water bottle leaks or sweats, you won't get a puddle at the bottom of your bottle pocket. You would probably want some elastic at the top also. There are probably lots of different materials you could use though. It might be worth heading to the fabric store just to ask them what they recommend.

I bought this mattress pad that’s waterproof and I can confirm the material used here is in fact waterproof and it’s also incredibly light weight. Perhaps you can buy one and alter it or locate similar fabric. SafeRest Queen Size Premium Hypoallergenic Waterproof Mattress Protector - Vinyl Free https://www.amazon.com/dp/B003PWNH4Q/ref=cm_sw_r_cp_api_i_aLv8Cb6CS3FKG

I did a quick Google search for you since my daughter also has a feather allergy. She gets hives from it.
Looks like Amazon sells bulk down alternative called enviroloft down alterative. Here's the link

https://www.amazon.com/Replacement-Filling-Pound-Power-White/dp/B00OJHPGRC?th=1&psc=1

You might try Bella Canvas: https://www.amazon.com/Bella-Canvas-Unisex-Sleeve-Charcoal-Black-Triblend/dp/B007M676TI

My wife has a screenprinting side-hustle, and these are some of her favorite shirts

I have this one (in my own language). it has a great collection of different fabrics (but no swatches).

This is what I was thinking

Here’s the link https://www.amazon.com/dp/B006ZBPNI2/ref=cm_sw_r_cp_api_i_c-02DbC0GTA87

Found a few. Will leave this post up in case others are looking:

Version 1


Version 2


Version 3 - with grip thread to minimize volume