Thank you Bowfanny! I've gone through and trimmed the chest pieces 1/4", from reading some other topics, I've trimmed from the inside, rather than the outside, which seemed easier to measure and follow. I also trimmed off about 3" off of the 3rd lame for the back plates. It seems most of what I've been doing lately is planning, ordering parts, tools and whatnot for what I want to accomplish. Oh, and templates, lots and lots of templates and modifying them to comfort.
I've got the flightsuit, and I've got the sleeves and legs hemmed to length. Going to wait on tailoring it until I can see how much will need to be taken in that's not covered. Really want to go for a heavy armored look here. Next item on board this weekend is the vest. Going with a duckcloth, doubled up and stitched to give an appearance of quilting. At the same time I'm going to try and knock out a duct tape mannequin while I have the extra pair of hands.
One question I have relates to the shaping aspect of the sintra. I'm using 3mm, but will be doubling up on some areas with the appearance of trauma plates, and generally giving some accents and depth to pieces. Is it preferred to glue the pieces together, and shape as a whole, or to shape them separately, and glue together after?