Didn't expect this much discussion early in my build (especially after I posted in the main threads... oops), but I'm glad to hear from future fellow troopers. It's awesome to hear more ROTKs are in the works!
As I've been neglecting this thread a bit, updates are in order (pictures coming once I clean things up a bit):
I've got most of the armor assembled and strapped in a semi-permanent fashion. I wanted some adjustability, so I used more velcro than I initially anticipated. After reading Jeff's thread, I decided to try velcro on both sides of the shins and forearms, which I like so far because it makes it much less stressful (for me and my armor) when they go on and off. I liked how Jeff strapped his thighs, abdomen and arms, so I used a similar method(s).
I bought some Flex seal (easiest to get) to test and it seemed to cover everything nicely, but like Michael said, I had difficulty gluing anything to it (Loctite glue worked...ish, but was stiff and brittle). I plan on sealing exposed parts once I am sure on my strapping.
As for paint, I was leaning toward Rustoleum automotive primer/filler and spray paint, but I'm not sure yet. I don't have the equipment or ability to do a professional job, but I'll give it a go with what I can get.
All in all, I'm pleased with the general fit so far, though I'll be interested in feedback once I do a full suit test.