I haven't looked at that thread in ages, so I wasn't aware the links were defunct -- but my point about there being a lot of information on that subforum still stands, if you go digging through the main thread.
There are patterns you can alter for the juuban and kosode; a robe will work, but several of the manufacturers out there make basic kimono or kimono-riff patterns that can easily be changed as well. If all else fails, look for Jedi knockoffs. You'll want to shorten the hems so they don't bunch up inside the hakama (knee-length or a little shorter is usually good). The white is seamed at the underarm, the black is open so the white shows through. It's supposed to be two layers, but I've seen people cheat with a white t-shirt and a false collar or similar things.
The juuban can be made out of white muslin -- you don't see much of it so it's not critical, and muslin is cheap and washes easily. For the black kosode over it, I've seen people use lighter twills, heavier good-quality broadcloths, and similar things; I used a raw silk because I got it cheap, but that was personal preference. The hakama is best made out of a medium-weight fabric that'll hold a nice crisp pleat; a lot of the commercial ones are poly-cotton blends. You can usually find a nice midweight poly-cotton twill for that -- black for everything except the himo, which should be white. Several layers of heavyweight fusible can be built up for the backboard.
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