Olga had a similar problem on her shins where they kept riding up and causing armor bites on the backs of her knees. The solution was to take a simple piece of nylon and sew it into the front of the boot where the pull strap is. I removed the pull strap very carefully and simply sewed a long piece of nylon into it. It was about an inch wide. I then took a strip of industrial velcro and stuck the fuzzy side to that. On the inside of her shins I placed the rougher side of the velcro. This worked amazingly well.
I might be able to grab a few shots of this later on to show you.
There's a guy in my Garrison who has been working on one for like five years or something. He's supposedly getting back into it and wants to have it ready for C6. I doubt it, but we'll see.
I think we've gotten everything we can from this thread and I can see that it's starting to head in the wrong direction. I'm going to head it off at the pass and close this up.
I got rid of my suspenders as well. They were giving me a back ache after trooping. I switched to a simple nylon webbing belt with some elastic to hold up the thighs. MUCH more comfortable.
I always use CA with accelerator. Creates a bond in 1 second and is very solid. Also, if you really have an emergency, with a bit of elbow grease you can still take the pieces apart.
If you really want to use the armor you have now, you can always reinforce it with fiberglass. This would be a lot of work to do every piece but would be easier than recasting it. Not to mention cheaper.
Why not posting the rest of the tutorial here so you don't have to send it out to everyone? I'm sure a lot of people would be interested in making their own.