I've started work on a fairly basic kit as I move up toward building an MMCC-standard one, looking to try out different ideas and methods to make something as reasonable and affordable as possible, so that when I start the polished kit, I can just go.
Currently I'm thinking about a fairly basic flak vest. My current idea is to take two 90/10% cotton light grey t-shirts and line one with the other to effectively pad out the vest. I'll also consider hemming up the sides as needed to fit me better. The kit will be Post-Imperial so I'm planning to cut down the sleeves to about 25% the original size and double layer the leftover edge so that I can attach the shoulder bells in a similar way to the Boba vest, and either cut the vest off at the bottom of my ribcage or fold the excess inside the shirt and stitch it up for four layers of padding. I'm planning to try using industrial velcro for the armor connections at first so that I can adjust the pieces as needed and take it off or put it on without needing to worry about a zipper or other connection. I'll also try to widen the collar and add additional stitching running lengthwise around the entire vest for texture and reinforcement.
Basically, my primary concern is if the idea I have in mind is going to be heavy duty enough to work, to maintain a solid shape and fit my form. In theory, the cotton will be thick enough and stiff enough with four layers of material plus the additional threadwork to provide a contrast against the flight suit material I'll be using (darker grey), but I did want to throw this idea out there before I grabbed the materials. I'm open to hearing differing opinions as well as ideas of how I can line the vest other than re-layering the same material inside the vest, and if there is another option for shirt that someone can recommend then I'm happy to hear it.
Here's the shirts I'm planning to use, super basic Fruit of the Loom 90% cotton 10% polyester t-shirt:
https://www.walmart.com/ip/seort/420147218
Vor entye for any help you can give me!