It occurs to me that some people may not know how to start making their own leg flares and holder, so I thought I'd at least share what I've done. See above for a picture.
I had a look at a few reference pictures and decided to go with CO2 cartridges instead of silver-painted wooden dowels. The dowels are canon (means movie-accurate), but the CO2's are shiny aluminum and look very mass-manufactured, sort of real-world useful. You can buy these by the box for CO2 air-pistols or paintball guns (you may need to be 18 or older to purchase these depending on your local laws). You might also get them empty from a paintball site if you ask nicely. Figure out how many it would take to go around your calf if they were spaced 1" apart. Double this number as each flare requires two CO2 cartridges.
(How many pieces of flare do you wear; do you wear only the minimum? :$ )
[Ensure that the cartridges are empty. If you puncture a full one you could do yourself serious harm.] :cry And please, please wear appropriate safety gear when doing so (safety glasses, face shield, whatever is needed). I don't want to see any of this...
Anyhow, cut the flares about where the picture below shows.
Next you can cut lengths of plastic tube (I used 1/2" CPVC plumbing tubing) which will fit inside the two halves of the CO2 cartridges. When put together mine were 4 1/2" long. Don't worry too much if there is a gap between them; it will be covered by the loops holding them in place later. You can glue or epoxy the parts together, or tape around the middle. Whatever works best for you, but think about how long you want the connections to last: one night, or the rest of the prop's lifetime? At any point you can clean them. I found nail polish remover will take the black logo and writing off easily. You should have something like this:
Now you need some fabric for the flare holder. I took a leg and a couple small adjustment straps with buckles from a pair of military surplus pants and made two long strips: one wide enough to be the back, and the other make loops to hold the flares .
Back Strap: Cut a strip of cloth about 5 1/2" wide and a little longer than needed to wrap around your calf (be sure to take added thickness of coveralls and/or boots into account). Turn the edges back 1/2" and sew. Fit it to your leg and add the closure of your choice (elastic, buttons, snaps, straps and buckles)
Front Strap: Cut another strip of cloth about 3" wide and make it much longer than the back strap (twice as long is more than enough). Turn the edges back 1/2" and sew. This strap will make the loops that the flares rest in.
Sew the two straps together at one end, taking care to make sure both good sides face out. Now move along the smaller strap 1" and sew across it. Place a flare under the small strap next to this seam and bring the small strap down over the flare to meet the back strap. Pin in place, remove the flare and sew across the small strap. This creates a close-fitting loop where the flare was. Pin both straps together and sew another line 1" from the loop. This is the start of your next loop. Repeat these steps until you get enough loops to cover your leg. Sew together at one end, add a loop for the flare, pin it, then sew and repeat until the holder goes all the way along your leg. Then leave enough fabric to attach your closure, turn back the edges and sew. It should look something like this:
Place your flares in the loops and decided how you want to attach them. You can make the straps a tight pressure-fit, glue them in place, or pop-rivet/ screw them in from the back side (it would be a shame to lose one on your first outing). Bear in mind your strap will cover the seam, and the plastic pipe can be used to space the cartridges farther apart if they seem a little short. I found nail polish remover will take the black logo and writing off the cartridge easily.
Next, congratulate yourself on your incredible homemade legflare set. Sometimes you just feel like you could take on the whole galaxy by yourself...
Big thanks to Wackychimp for hosting again. Hope I'm not wearing this out...