So excited to start this build thread! I currently troop as a Jawa with the 501st and a Jedi with the Rebel Legion. I've watched my teenagers build armor, and decided it was something that I wanted to try. We have one Shadow Scout and several Biker Scouts in our garrison, and they've been great with advice.
Armor was created by a friend in Pittsburgh; still waiting on the chest armor and the helmet. (Regular size chest armor was going to be way too big; working from smaller molds now.)
I decided to save money and sew my flight suit. (This may not have been my best decision, but it's summer and I have time to work on things. Plus, I want to try and keep the cost down where possible -- and this ended up around $40, so that was a bonus.) I based the suit off of Simplicity's pattern #8722. My big mistake was that I didn't think to alter the height of the pattern before starting. (I'm the type of person who can follow literal sewing directions, but I don't have the same sewing intuition that my mom does. I could have used a big heads-up in the directions that said something like, "STOP! Measure torso length and adjust pattern accordingly before cutting fabric!")
The thing is, I'm only 5'2"...so as I was putting the suit together, I realized that it was ridiculously long, even though it was based on a size small. I didn't want to start over, so after a lot of thought I decided to cut the suit in half (ugh...) and custom fit the center where a belt would be. The thing that kept me going was remembering that the torso of the suit ends up being totally covered anyway, so I doubted that I could mess it up beyond repair. In the end, I'm pretty happy with how it turned out.