thanks for the compliment foxbatklr!
i actually use rustoleum dark gray automobile primer, then rustoleum aluminum spray, then silver leaf rub n buff applied copiously by hand (then buff it out with a white cottom t-shirt until that baby is SHINY!!!!).
works like a charm for me, though you can tell by pictures that the all rub n buff method is equally impressive or moreso.
BKBT and RA make nice, accurate, reasonably priced vests by the way....
I used a t-shirt pattern for mine, got rid of the yoke and sleeves and modded the neck. I drew my own pattern for the cap sleeve. I sewed mine out of dark gray "marine/headliner" vinyl - it doesnt have the cotton backing and has a leather-like quality to it. the only problem is it doesnt allow your torso to "breathe" - so youre basically COVERED in sweat when you take it off.
good luck!
sean