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.
I don't know if you were there during C5 but did you get to see the sexy wampa? She didn't leave much to the imagination.
I say the more scantily clad women running around the better.
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.
I used to just wear contacts when I trooped. Now that I got Lasik I don't have to worry about it.
There is a member of my garrison and a good friend of mine that pulled out some lenses out of an old pair of glasses and mounted them to the lenses in the helmet. You could try that out.
Any of the TE Derived armors should be fine. ATA, AP, and T/MC are very readily available.
My gf's was an ATA and she's 5'4. It took a lot of work, but it looks great on her. Good luck!
Instead of resizing the chest you can resize your ab plate. I don't have the pictures up yet because I've been lazy but I'll be posting them in the modifying armor for women thread. Basically you can trim the part just under the ab plate that is part of the cod piece. I took a good inch and a half out of my gf's and it made everything fit perfectly.