Did you hot-cut your fabric pieces, or (alternatively) melt the edges after cutting? Uncoated fabric will fray easily.
I used some commercial VB 'socks' - don't recall if they were Stephenson or another (OR?) brand- on several trips and they held up just fine. They were made with PU-coated ripstop and sewn with simple seams with fairly generous seam allowances (1/2" or 5/8"). The seam allowance just laid flat and didn't add much bulk.
I wouldn't seal the seams on socks because of the problem of adding stiffness and bulk to the seams- I'm always wary of blister problems. Anyway, I don't think any 'leakage' through seams is very important in VB gear.
I find that silnylon has a stiffer, more crinkly, 'hand' (aka texture) than PU-coated ripstop; I'd use PU-coated stuff for socks if I were choosing.
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