Tell us about yourself!
Re: bias tape. I just found out about a handy little device called a bias tape maker (Experienced sewers are probably well aware of it, but I want to share the thrill with fellow novices). They're inexpensive, especially if you're planning to mass produce. I'm still waiting for it to ship, so maybe other folks can speak to its effectiveness.
I just saw this - cool on you for getting it up so much quicker. FWIW, I missed the measurement and made it at 5.5" - luckily, it still works. I'll switch, though - thanks for catching that!