RE: Need new carrier for my 13 month old or Recommendation for sewing one
It's definitely possible to make a comfy carrier! Not that I'd know myself, but of course most of the best carriers out there are home-designed. I think a mei tai style carrier would be great for you, they are awesome for older babies. Have you been to the DIY board at TBW? The mamas there can definitely help you with finding a pattern.
If the DIY doesn't work out and you're looking for cheapers MTs, Sachi MTs are one of my favorites and they are great for older and younger kids. I have a code for free shipping at a site that still has the "old" $65 price, so that might feel more reasonable...
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Vida
Mommy to DS (5), DD (3) and new DD (<1)