Crap. I can't do anything right today. Let's try again...
Yeah, the real issue for me is the legs. The ab/back plate has LOTS of extra material to cover my torso, although I must admit that there is very little to spare. The arms are the same way since the bicep plate can extend fairly low beneath the shoulder cap (where once again I use most of the available space). But the gap between the torso/thigh and also the thigh/shin plates is where I have the problem. In a perfect world, there would be longer parts for both, since my sniper plate is below my knee. So "surgery" is really the only option. I am not sure, however, that I could do it well enough to avoid an ugly horizontal seam. Do you know of anyone who has done that successfully?
By the way, regarding being a killer Vader, I also have a Vader as well, however, it is not yet official in the 501st. I am having the leather garment tailored a bit since the former owner had more substantial "girth" than I do.