To get the size, I just traced some existing clothes I have and I sided a little bigger since I'll usually be wearing this over other layers. Initially the front and back halves were identical pieces of fabric, but then I cut the neck deeper on the front, cut it open down the middle and enlarged the arm holes towards the front a bit.
Everything I've got I ordered from QuestOutfitters.com. The vest is 70D nylon and I'm using the gutterman thread and standard black edging. I also ordered some webbing and buckles for the 2 buckle closure I'm going to put on the front.
The air bladders are 70D heat sealable nylon, also from Quest and then I need to get valves somewhere…maybe just from thermarest's repair kits, but spending $36 ($12 x 3) to get three valves is a lot of money considered all these materials was only $24. I'm creating three bladders that have baffles inside so they don't get too round, and it's hard to explain, but sides are offset so they will sew nicely into the vest without bulging into the inside area. I might get the first bladder done today and then I'll post pics.