Since no one had metal boning in stock and we didn't have time to wait for an on line order to ship, I had to think WAY outside the box to finish the wedding dress in time.
Why not try the Dollar Store? When I walked in the door I had no idea if there was anything in that store that could be used for boning. Found the case knife blade was right size and hardness.
The picture shows pretty well what I did. Put the handle of the knife in a vise and clamp down securely. Use hacksaw to cut the handle away from the blade. Smooth down the rough cut edge with a hasp. Cut a piece of fabric large enough to wrap around the blade and sew it around three sides. Insert the blade/boning and sew in place.
Watch for the DIY Cotton Bride couture wedding gown tutorial post coming soon!