on TCF, check out eggroll's threads about converting a costumebase flight suit to something better.
and if you're looking for a cheap helmet, i've got a fiberglass fixer-upper that i'd let go cheap. it's no where near as good as the ones that a member here makes, but it would be something around 1/8th the cost
dgasser is a big POC for all things BSG. He makes the holster, racerback shirts and O2 sensors.
The biggest hurdle is going to be the fabric. Right now, it's at $52 a yard. There is a thread on ASAP: http://propreplicas.yuku.com/topic/15381
The pouches are going to be impossible to find. Let me caveat that by saying the correct versions will be impossible to find. There was a run on ASAP with the people who make them. The current versions have snaps, not velcro like the show.
Get with Jose (gotmaul) for the correct BSG75 patch.