PROGRESS!! 
Sorry I have been off of the boards for a while (between my folks being up from AR and getting the house ready for a week before they did! 2 Ren faires (one of which I won the cosplay contest for guys over 18 with my Jedi costume!

)

But I have made some progress!

(These may not be in the exact order that they were done but you will get the idea!

)
So the first is cleaning up the seams on the backplate/pack, I decided to hide all the rivets with Bondo...
Round 1:





And round 2:



I also installed the battery box for the "Targeting nano computer" that will be mounted on the right shoulder of the backplate...
First was to cut an opening for the battery box that was a little wider than and slightly shorter than the battery box:

Next I cut a cardboard box to protect the battery box and allow me to remove it from the backplate to replace the batteries and also maintain access to the power switch, then taped it in place under the fuel pack:


and with the battery pack in place:

Now, with the battery still in place I filled most of the void with expanding foam:
(This was all done prior to/during the bondo work!

)

Next was all the previous Bondo work done...
Now you may ask "What is this Targeting computer you speak of??"
I'm glad you asked...
...This is it:

Well, the beginning of it anyways, this is the template on the box I'm using for the holes to be drilled for the LED's
And after the holes are drilled before being fitted with the light string:

Here's the light string after being shortened from almost 6' long!

But prior to wiring it up I had to shape the bottom to fit the curve of the backplate (it won't be glued in place in case I need to rewire it for any reason, I'll be using machine screws to hold it down):


And with the lights installed with hot glue:


Lights ON!

And a quick vid:
I also got some polyester dye and re-dyed the flightsuit...
...in a crockpot!!!

Think it came out pretty much exactly the dark gray/charcoal color I wanted:

Still have some additional progress on the gaunts with electronics for the LED indicators and the viewscreen, but sadly won't make my original Halloween night deadline (I'm not gonna rush just to get it done, i want this to be the best kit it can be!
So what do my Vode think???
Am I doin' alright with the ideas? Also, any suggestions on how to mount the backplate would be appreciated!!! Harness?? Velcro?? Magic??