Colored bars
From CosplayWiki
Where can I find the pieces of the right color and length?
There is most likely no single Lego set that contains all the required pieces. I recommend searching your collections to locate pieces. If not, you can always find similar pieces and paint them. However, if you paint them, the coat of paint may make it more difficult to snap together.
To find a smooth plate of the right color and length is a difficult task. Most smooth plates come in grays and whites. Reds and yellows are fairly common as well. Greens are perhaps the most difficult color to find. Lego.com sells bags of the tile bricks (http://shop.lego.com/leaf.asp?cn=104&d=18&t=7) but it is a fairly expensive option.
For the pieces with holes in them, you can find them in most Lego TECHNIC type sets.
Do you suggest sewing the Lego plates to the jacket first, then putting on the flat colored Legos?
Or put on some Legos then sew on after?
Sewing the base on first is a good idea. Lego TECHNIC bricks are advantageous since they have holes. However, you can use regular plate bricks and wrap thread around it and sew it on the costume. Upper layers of plate bricks will help clamp down the thread and securing the pieces to the costume.
What colors do the Lego flat plates come in?
Yellow, Red, Black, White, and Gray are very common. Blue is a little rarer (but I don't think this color will be needed). Green bricks are very hard to find, especially a smooth plate brick.
What sizes do the Legos come in (how many dots or whatever you call it)?
The base plate bricks usually come in 2x4, 2x6, 2x12. (I suggest using these since others like 2x3 and 2x10 are impractical).
The topmost layer smooth plate bricks are normally seen in 1x2, 1x4, 1x6, etc. I wouldn't suggest anything longer than a 1x6. 2x2 square tile plates are also common so you may use those if needed.
Why are your colored bars so thick?
The reason they are so thick is to add stiffness. Two layers of plate bricks will fall apart with motion unless you glue them together.
