The dog collar on my impending rescue got me to thinking - for those of you that don't know how, you can make your own halters for roughly 2-5 bucks (depending on the rope you buy). I buy 100 ft of rope at TSC for 14 bucks, and I can make about 5 halters out of it (more if you have smaller horses - most of mine have big ol' drafty heads). You can use 1/2 or 3/8 rope depending on how much "bite" you need. It's hard the first time you do it, after you get the feel of it the first time though, it's a piece of cake. I can make 5 custom halters in my horses size in a little over an hour. The hardest part of the whole process is the fiador knot - and you don't HAVE to use it.
Website to walk you through: About.com: http://www.frontrangefrenzy.com/horse-halter/make-rope-halter.html
Apolgies if this has been posted before!