We had to replace all the flaps in out 1986 - looking at the new ones I suppose you could make your own but you would need a sewing machine that does heavy duty work. If you have access to one of those, it would probably be doable. I wouldn't want to try it with my regular home machine, that's a lot of layers of heavy material to go through. If you do try it, make sure to report back, we all love to see pictures!
Also, if you haven't already, consider becoming a sponsor. $12 a year is a pittance for all the information and help you get here from some very nice people! It's the only board I have every paid to be a member of, and it's worth every penny.
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