Just found this. Really impressive work! Did you figure out the pattern yourself? I'll be following this, have been toying with the idea of making a couple of motorcycle-worthy jeans that look good enough to wear around all day. It seems like you've pretty much decided to go with the chainmail, which I agree would look badass. If it doesn't work out, I had another idea: what about adding a layer of the non-stretchy abrasive-resistant stuff over the stretch material, but using large overlapping pleats to give it some room to expand? Think insect scales.. If you're interested I could quickly sketch what I'm thinking, probably not explaining it very well.. Are you going to chainmail the whole crotch area? Can't be very comfortable.. and won't it scratch the tank? Anyway, here are a couple of resources I have bookmarked, which sell outdoorsy textiles. Maybe there's some waterproof fabric you could use? These guys sell kevlar! Profabrics Shelby Ooh, now I want to get my hands on some reflective stuff to pimp my jacket! Dammit I don't have time for projects now!
Yeah I figured out the pattern myself, having the duck-tape mannequin made it very easy, just hold up an oversize piece of fabric and pin it to the mannequin. The chainmail wont cover the whole suit, only the main abrasion risk areas, outer arms, elbows, shoulders, back outer legs, knees and bum. The problem with pleats is that they tend to collect water and they don't look very neat. Something like scale mail with fabric scales might work though. I have those sites bookmarked already, in fact I have samples from extremetextil.de and shelby including the kevlar, it's pretty thick stuff. Moriquendi