My first MYOG PFD (entirely inflatable) ended up in the recycled materials heap after dying the death of the thousand modifications combined with never really getting the valves to stop slowly leaking.
For a second attempt, I was going to go with bottles like the late MLD "The Thing". Based on some trial mockups, I couldn't find a way to use bottles in the front without interfering with either the spray deck or my paddling. Ultimately I came up with this PFD. It's two layers of 0.6" closed cell foam in the front and one layer in the rear plus a bottle.
SPECS:
Weight: 7.9oz
Float (Front): 5 lbs
Float (Rear): 2.3 lbs + 2.2 lbs (air)
Total Float: 9.5 lbs (vs. 14-15 lbs for a proper whitewater PFD or vs. 5 lbs for a slalom racing vest).
MATERIALS:
Fabric: 70D nylon
Straps/Buckles: 1/2" (from Quest)
Accents/Pockets/UL Cred: 1.2oz cuben
Foam: Wal-mart cheapo mattress
I'm also working on a second front portion with just a single layer of foam. This can be used with the current rear sans a bottle, which drops total float in half but reduces bulk for calm trips. That should weigh ~6oz.

Rear section with a bottle. Velcro is to fold it flat when not in use.

Front section. There was a front pocket but I ripped it off because it becomes useless when the PFD is curved around my chest. I should have planned that better.




