I feel for you Tony! Been there... All I can say is don't give up!!! 
Tandy (and other leather stores) do ship their stuff! Trust me on this! My nearest Tandy is quite a haul for me as well! Their hours aren't good for me either. I think I've been there 2x during my Zam project, the rest of the time I ordered online.
There is a sticky thread here of all the Zam parts - which can serve as a "To Do" list ...
As far as sewing ... If you have a machine. Try it out... sewing a "muslin" - using the stretch denim and see how it works out. If you can't stand it... you can still hire a seamstress. If it turns out - It's money you've saved... right? 