Great work on the build so far!
I had a little issue myself figuring out the velcro calf closure- mine were initially a little thick as well. I went to the hardware store and was able to find some very thin but high strength velcro so it was able to hold firmly the spots on the calf where it wants to pull away. It took a few suit ups and a troop or two but it also did adopt the form of the armor curve and also became more compressed.