I know you've already decided on a direction for the body armor, but did you consider something a little thicker/sturdier like EVA foam at all?
If you mean the stuff that Pete Mander used for his Elite, then yes. I'm way ahead of you. I already got a pack of 4 of them. XD I plan on using it for the chest piece, the cod, as well as the black stuff on the thighs. The more comfortable the better.
@Aether: I hope to finish my armor completely by January, and work on my weapons from there till May. >w>