1. Do you want one-piece or two-piece? It’s personal choice. Just make sure it looks like all one piece.
2. Lots of folks use leather but I don’t know weights so you’ll have to use your judgement on what will be strong enough. Laces would probably look better than Velcro but you could also use leather straps.
3. Rope, paracord, a fabric sash, lots of options. Make it wider than your belts; 5-6”.
4. Watch The Clone Wars cartoons or search the characters. Look at the 501st clone CRLs, lots of kamas there. Basically two rectangles that you can vary. Also, the kama doesn’t replace the cod, you’ll need a loincloth, too.
5. Sounds like you answered your own question.
6. What kind of gloves does your character wear?
These are all basic questions your Ruus’alor should be able to help you with quickly. Look through WIPs, get ideas. The great thing about this club is the customization. There are minimal rules, make your kit your own!