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hmmm... if he won't use a foot box (i love mine<g>) how about a couple elastic straps near the foot end that would go under the pad?
if not, you may just need to make his quilt a full rectangle so...

powder like that would even sift through some thing down proof i would think:confused:

i'm not sure how to best answer that question but i'll give a couple thoughts & we'll see what the others have to say.
i believe a lot of folks would suggest a tightly weaved fabric.
a DWR...