This is why I love uncannyxmen.net, their spotlight pages give you a good break down of costumes. Here's Sam's costume gallery
from there, you might be able to talk him into #9(it's varients) or #10, possibly #13?
I think, if you're going for ready made 9 or 10 would be easiest to assemble. It's pretty much leather pants, a shirt and a jacket/vest; the jacket/vest being the only thing you'd really have to modify too much. Well, and the boots, but still....
~I've gone to look for myself, if I should return before I get back keep me here!~
Costume list 2009: Finished
17 initially planned :: 15 completed :: 6 moved to next year
Costume list 2010: Started
6 from '09 :: 9 initially planned, now up to 22 total