Hi AJ,
just wondering if you had a chance to check out Samplit
http://www.nikkoid.com/index.php?option=com_content&task=view&id=97&Itemid=1 I've been playing around with the demo version for a while this morning.
You mentioned you had Cool Edit , but not sure whether it does the same thing as Samplit.
It appears to simplify the process of creating the samples and then converting them into soundfont format.(It also saves in Halion, Kontakt , Reason etc formats.) Just as an experiment I sampled part of my Clavinova's drum kit this morning. Only took a few minutes to sample it and save it as a soundfont. I still need to do a bit of experimenting as I don't fully understand all the settings.
A better soundcard than my laptops internal one would also help.
Anyway, I'll leave you with it.
best wishes
Rikki