Thanks guys for all your responses. It really helps a lot.
I know you guys have been at this a lot longer than me, but I have a few thoughts and comments on what I'm planning to do.
I'm an engineer by profession, so the chest box would have "functions" that would have to do something in "real life" even if we didn't see it actually "functioning" in the few minutes that we actually see Vader on screen (hypothetically).
On the ESB box, there are no less than 9 switches / sliders and 5 lights. My goal is to have these switches actually work and do something.
So, above and below the blue lens, there are 2 little ( i guess ) slide switches. I intend to have one control the blue lens / light and the other control the red lens / light. ( so I can be cannon if I want).
Also, between the "rocker" switches there are 3 more of these slider switches. I'll use one to turn on the led driver board. I have bought the chest box lighting board & led's from Jim at Hyperdyne Labs. The other 2 I don't know yet. As for the rockers, I am planning on molding the rocker switch and attaching it to a standard rocker switch cover so these will be movable as well. As you all probably know, the rocker switch shape on the prop is very unusual and I have not had any luck finding a stock switch of the right size.
I am designing everything in CAD (Pro/E) and have a source for making the parts using SLA. I am also building my belt boxes the same way. The hardest part is getting the exact dimensions for these parts. I am having to resort to measuring off of high res screen caps and some of the ref material that all of you have on your web sites.
As I get a little farther along, I'll post some pics of my progress ( I have to be done by C4.. )
Cheers,
David