Hi Chris,
Re "HELP: Vader Breathing on your costume". Well, if that is happening, I guess you'll just have to put up with it.

Sorry, that's bad I know.
I used this:
http://www.radioshack.com/product/index.js...rentPage=search
You can get them in Canada at The Source I think.
They actually sound decent, much much better than the stock Rubies thing. I connected them to a cheap MP3 player with Vader sayings and breathing. I have some that I think are pretty good and you're welcome to them.
If anyone has Adaptec or Roxxio cd/dvd burner software, there should be a merge track utility. Using that, you can merge copies of Vader breathing into one very long file. Or, you can have Vader say something, followed by as much breathing as you would like to add to the file. That's fairly realistic and allows you to find another comment on your MP3 player that might be suitable if you are trying to simulate Vader interacting with folks. I've done that with a number of Vader sayings, its quite cool. I have a particularly nice "Give yourself to the Darkside" that is loud, deep, clear, minimal background sound with no noise.
I initially attached my folding speakers right to the inside back of the dome with velcro. I left the speakers in their case because they have nice resonance and bass that way. It sounded great because Vader's voice and breathing sound came from where you would expect it to, and happily the speakers were not readily visible. But, they do add to the weight of the helmet right at the back. So I'm trying to think of a better way.
I think an Ipod with the screen would be the best MP3 player. I'd expect that with the screen, you could quickly select a suitable track and play it. Some cheap MP3 players should work fine for just breathing, but if you want to be able to quickly select different voice tracks "on the fly", you need something that's not cumbersome to use with a gloved hand. And the Ipod comes in black, so you could discretely place it on your forearm under the flange of your glove, for example where it could be readily acessed.
Dave