My research has come through images for the most part, There was a insanely detailed analysis on a website called " The Film-welt Collection" that mysteriously disappeared recently. As for the fabric it is some sort of Vinyl spandex , it has stretch which is a pain to sew and work with as you can imagine. I learned some hints and tips from Max C who I spoke to in person in Vegas about this.
As for the RPF post, I never saw it but did hear about it a long time ago from a member here on one of my early posts announcing I would be doing this project.
I did however learn that some images of the making of this suit were posted in a magazine some years ago. I however never saved this source so I cannot find it.
Online images through the sales of several of the suits helped too, such as prop stores archive of TPols suit…
As for the suits themselves, I have realized that although obvious the suits may needed to have been made specifically for certain actors, that they all have different positioning of the cords as HMS noted were vaccuformed, I do not have one yet but Max C did say they did do so.