Love the project, first thing I'm going to try is gonna be a Marine. As for your friend, you might want to try an olive drab or brown T-shirt instead of going shirtless. It'll act as a rashguard, if nothing else. I don't know how the vest and armor feel, but if they act anything like a life vest (I sail for fun, that's why I make the reference), you're going to want a layer of cloth between you and it. Or him and it. Whichever.