Wow...allot of good information in these posts. I need to look into a new holster again but hate that you can't try before you buy on custom holsters.
I am 5'10" and 160lbs. and have had a rough time finding a comfortable IWB holster as well for my XD 3". I tried a VMII a couple years ago and I was left with a rather nasty bruise along with an angry sciatic(sp?) nerve; I never wore it again. After spending that much on a holster that didn't work for me I stopped looking at the custom units and have yet to find an off the shelf one that works.
Until I locate a holster that works for me I am stuck with a .38 snubbie in a pocket holster in the summer and the XD in an OWB in the winter. Not exactly my first choice but at least I am armed.