Weaving experiments to produce 1/2-twill fabrics from a common, size-free cotton warp have been conducted under mill-like conditions on a modern high-speed, flexible-rapier weaving machine. More than 100 yards of fabrics of the same warp density but varied pick density were produced without any warp yarn failure or breakage, deploying weaving speeds up to 500 picks per minute. This certainly demonstrated for the first time ever that the size-less weaving of 100% cotton yarns on a modern high-speed weaving machine was at least mechanically feasible for certain fabric styles. However, as it was reported in previous conference, the quality of the size-less fabrics produced was not satisfactory, mainly because of a random formation of unsightly, tiny fibrous balls that first appeared on the fabric surface at or near the beat-up. Although the woven greige fabrics were manually inspected to determine the frequency and possible causes and remedies of the stated tiny fabric defects, the fabrics could not be objectively tested before the historic, 2005 hurricane Katrina caused massive flooding and severely damaged the USDA-ARS research facilities located in New Orleans, Louisiana. However, the fabrics were retrieved from a flooded lab and objectively tested as much as possible at the Textile Department of LSU University in Baton Rouge, Louisiana. The comparative test results of the size-free woven fabric and the conventionally sized (control) fabric, along with the current, overall status of size-free weaving research, will be presented at the 2007 Beltwide Cotton Conferences in New Orleans, LA, USA.