So how did the garb hunting go?
I've mostly bought stuff online. Some things I made. Tabards are fairly easy. Couple of yards of broadcloth with another yard or two of muslin or other cheap stuff sewn opposite as a liner. Cut a hole for the head. Stitch the seams, pull over the head and belt around the middle. Voila, a tabard. Covers unsightly modern T-shirts and sweats.
Ebay has garb online. Some pricey, some not too bad and some used at better prices. Some websites are run by women in historical reenactment who love to sew and create and sell garb. Some have decent prices especially for instock or used stuff.
www.garbtheworld.com has all kinds of garb and instock stuff. Some is not too expensive. Another source I have used is a yahoo group called 'garbforsale' (I believe) You can do a group search for 'garb' and it will usually be the first to pop up. They are enthusiasts, many are SCA, who sew and sell what they make. Some at decent prices. Many are in California so shipping is quick and not too expensive.
Cotton is cheap, but linen is period and is very cool on the skin. I used to own a linen T-tunic and have regretted selling it.
Just some odds and ends about garb.