Jim, the 541 (probably all Hoover bags of a certain time span) bag is a fairly straightforward pattern of 4 pieces seamed together, as you have discovered. Sewn & assembled in stages as the factory Gals did should produce a fair and convincing copy.
I was fortunate while in Minneapolis in November to accompany Fred & Robert when they picked up a fine original condition machine. My excitement was also that I would be able to examine and measure the bag at my leisure.
Back at the house we took the filled bag to the workshop and carefully vacuumed it out and cleaned it.
I then laid it out flat in various positions, photographing and recording accurate measurements along the way, with the determined idea that I would - WILL - produce a copy in ivory Duvteen of the correct weight.
Sketches were drawn with the intent of drafting my own pattern. Working at a Theatre with it's own in-house Costume Department I have access to materials and in fact about 10 years ago made myself a black Duvteen raglan sleeve spring jacket to recreate my favorite jacket I had as a 12 year old. The scraps were salvaged from costumes made for a production of Hamlet. So I know the exact material is still available (although perhaps not from a standard Mall fabric Store).
Anyway, Fred magically produced a book full of Hoover Factory Photographs (I think he said he got if from John Lucia many years ago (?) ).
I took two quick photos of the pages that show the pattern pieces being cut out with minimum fabric waste and the fabric being examined for flaws (pinholes). Passing this examination I expect the pattern was then placed in a silkscreen frame for the printing. And off to the sewing room we go...
Basically a contoured bag tube reinforced at the bottom with two leaf shaped lining inserts, with the bag top an oval disc, all secured and supported by lengths of four-layer 1/2" straps made up from the extra cloth around the pattern pieces. These are 1.25" strips of whatever length along the straight grain, folded upon themselves, then folded again and stitched along both margins for a strong 1/4" belt, inserted in the bag seams before sewing, looped and sized for the location. Sometimes the metal hooks were placed before sewing or added afterward.
Taken altogether there is more than enough information to faithfully re-create the bag, supposing one can also silk-screen - or hand letter - the Hoover Logo.
Series of photos to follow...
