We thought about that, a "cheap" bean bag chair is roughly $20 a pop, and about 6 to 8cu/ft. A little to expensive for my tastes.

Zippers are pretty cheap, and it's nice making it using a fabric you chose. Definately going to attempt to call some molding places on monday, and see if I can "bulk" buy 150+ cu/ft of the stuff... can you say lots of boxes?