I'm with you guys...I like Pinder's pattern best, but I think it should be on a white fabric, or at the very least, a very light baby blue...most of all the film shots and posters I have (or have seen) give the impression of the shirt being either one of those colors....I think the perception of the general public would be the same either way; they will know who you are supposed to be.
The scale of the hexes, based on the interregation scene pics, look to be 1" to 1.25" across the facets.
Another question I have is the type of fabric it will be...Ledger's shirt seems to have a slight sheen to it, like satin or a nylon mix...it's not plain old cotton.
Sinister... those shoes are bitchin', man...excellent reproduction! Where did you get those socks? Hand painted?
So...are we down to a reasonable cost-per-yard estimate yet?