So we are thinking of using a black jersey knit for the mask/neck seal. Thinking lycra might be too reflective for it.
Also, i assembled the main portions of one of the 3d printed hilts, and as cool as they are(and awesome when we can superimpose blades on them), they are just too small to install any type of electronics into it. So on to plan B.
Plan B is to custom build sabers according to the circular sabers shown in the CRL. I am using PVC electrical conduit that comes bent from the store, and some pvc couplers as well. It is a pretty easy hilt to manufactur, and they will provide ample room to install a soundboard, high powered led, and batteries, alonrg with housing a blade.I got most of the components from The Custom Saber Shop, and the polycarbonate tubing from Amazon(ordered 6' of 1" OD, 7/8" ID, and 1/16" wall thickness for $21). This will allow me to cut the tubing in half for both sabers being 36" each(i may end up cutting it down to 32" but we will see). I am also gutting a hasbro blade builders saber to use the speaker and soundboard(with plans on upgrading later). Luckily, they are on clearance at walmart for $10 each .
Here is the partially assembled 3d printed hilt.
The CRL photo for reference
My findings at Home Depot compared to the 3d hilt.
And where i am at now. I still need to add another section of pvc, and then another trimmed down coupler.
Also, for the vambrace straps, i did find this online, and was hoping to get everyones thoughts on them. If they wouldn't work, i will manufacture some out of sintra for now, and continue searching for metal buckles.