Just saw this thread and I must say that your statement about it being an undertaking is so right on. I have made/purchased an accurate ROTJ Han costume and am currently a member of the rebel legion. When i started out, I had no idea what i was getting into. I just wanted to make an accurate Han costume... But I am way to detail oriented, couldn't not do it right.
I have a thread in the RL on the parts I used, and I would recommend checking out the stuff over there. There is a TON of info! I wish I would have read it all before i started.
All that said, i have some info on DONT's
Don't get the crppy pleather holster from "starfortressproductions" (i think thats the name...) on ebay. It is a regualr belt with a "Y" harness. Overall crappy and I think the guy who produces might be a sex offender (no joke, not slamming him, did some serious reading on the guy).
Don't buy the "german officer boots". I think it was mentioned above. Crappy for a han, great for an X-Wing pilot.
If you have the sewing skills, Don't buy anything you can make yourself. The boots/holster/and Dl-44 are gonna cost you enough. If money is not an issue, go nuts.
Anyhoo, if you have anyquestions, hit me up! Good luck!
Here is the link to the my han costume on the RL. I think you can find it unless its in a members only area...
Rebel Legion :: Viewing costume :: Han Solo