lolitablue, I don't know whether it will cut the cost down... I found this website, looks like all it needs is an elastic band to hold it together
http://www.craftster.org/forum/index.php?topic=44540.0;topicseen
that is a great idea but I've found that some people cannot stand the pressure of the elastic on the nape. It would not make a difference as far as cost, actually, it would require more fabric than the one with the base plastic headband. That will also depend on preferences but my Mom is a pro in the headband/plastic band kind. Any other choices, she would not be able to help us. T4p, though!