Ok so I rewickered the pattern to a "2.0" version today. I opened up the size by 1/2", and removed the hem lines down the side. This simplifies construction, since you only have to hem the tops on each end. Since the JCP folds from wrong side out anyways, the side hem is needless.
jcp__compact_pattern20.pdf
I cut a Charlie prototype and sewed it up. I found an easy way to stitch the "ears" of the bellows was to fold the cloth over and mark the triangles with silver sharpie, using the pattern. This ended up being much easier.
Here's the Charlie version, after sewing, but before flipping it inside out. It's top down, and bottom up, in this picture.
Here is the older JCP Alpha (on left) and today's Charlie (on right), shown next to my DSG Holster with the OEM Foam Pad. Note that opening up the pattern and removing the side hem enlarged Charlie a bit, which was the intent. I have the tops pinned, just to fiddle with amount of poly-fil to get the right stiffness. I'll sew up the top hem tomorrow once I'm happy.
Many thanks to @
Clusterfrack for this awesome idea. I really appreciate it.