Hancock of Paducah's and connecting threads have nice fabric at reasonable prices, look at the quilt kits too. Give him the dregs of old clothes (like pj,s undies and socks, exercise etc) to take with him, and not to bring home. Or have him wear 4 or 5 shirts, socks, pants on his trip back to lighten his luggage (hehe). An expandable carry on will help with fabric. Check the airline about number of carry ons and size, lots of fabric can be carried on. Did that a couple of years ago returning from NH.