i am in canada, so i cant help much with where to get stuff.
but i use mostly recycled stuff except for the PUL part. my inners are all microfleece since that works really well for us. my diapers are all with velcro but i am begining to hate them since even with laundry tabs, they seems to form a diaper snake in the wash, so i am now switching to tie diapers. i dont hv a snap press but most moms hv the KAM snap press that you can purchase from Very Baby (i think) or Serena in china but i think she has a wait list for that. An arbor or drill press if you have one can be modified to be a snap press.
i make my pockets with front sham opening since i dont want to be touching the poop when i unstuff them..lol my DS's pockets has gusset since he is EBF and his poop is runny. gussets are great to keep the messes in but a pain to sew and you dont need it if your DC is on solids.
there are as many free patterns as they are purchased patterns. for me, i use some recycled fabric (old bedsheets are the best) to make diapers from 3 different free patterns, Wee Weka, Ottobre and Rita's Rump Pockets (RRP). My DD's best fit is on the Ottobre so her stash is made from that. My DS's best fit is from the Wee Weka so his stash is from that. I've made an RRP and love the pin part but my DH wasnt not keen on the pinning and when i turned them into velcro-ed diaper, even with shortening the wing, it was still a little bulky at the crotch.
http://diaperdivas.proboards57.com/index.cgi? this site has a ton of info, you need to register though.
good luck!