I'm not of much help regarding the costume construction but I can say that I dig this idea! It sounds really cool/unique and still recognizable! I can't wait to see photos if you decide to do it!
*~Cosplays in progress~*
Masamune Date - Sengoku Basara
Eren Yeager (casual outfit) - Attack on Titan
Sanosuke Harada - Hakuōki: Shinsengumi Kitan