Well my hand plates are E-6000ed to my gloves. But for the thighs I used 2 inch wide elastic and it works great. You get it at fabric stores and have to buy it by the yard.
Good luck.
Guys, this thread is over 3 years old. Alot has been found out about movie suit and costume kits over the last several years.
If you feel that passionately about it feel free to start a new thread. The thread is now closed for necroposting.
So far so good. Details that need to be seen for an EIB app is to make sure there are no side gaps, blaster pics, and more helmet pics.
Congrats on joining the Legion.
Most armor makers sell replacement parts.
If you really want to make your own, you could get some sentra and heat it over the ends of the pipe letting it sag into the pipe, and form it to the outside. Then trim to length.
Here are a couple tutorials. They are for models but costumes are just big model kits.
http://www.starshipmodeler.com/tech/aw_wx.htm
http://www.firebladecomics.com/guides/battledamageguide.html
http://codyscoop.com/ht-damages.html
And remember sometimes less is more.
Get in contact with Star Garrison and go to a larger troop and look over all the different armor there. You may not see every maker but you should get a decent sampling.