I know you said Sanswill is out of your price range, but I'd honestly say they're worth it. I know the girl who makes them and they're gorgeous. When I'm not a broke (okay, LESS broke, I'll always be semi-broke because of my pony) university student I plan on getting one. There's also the fact that I live in Canada, and therefore SmartPak isn't an option for me.
My pony also has a weird head, and the girl behind Sanswill has assured me that she'll be able to make something that fits her
I tried the cheapie route the first time (under $50) on a semi-custom and it was just bleh. Decided to plurge on the Sanswill and it's light years better. Amazing quality, fabulous fit, and the colors are perfect. A little pricey but so worth it. Never should have wasted the money on the "cheap option" in the first place! You get what you pay for.