Okay, first of all, I am one of the above mentioned "sewing inclined," and probably also a little masochistic. I love to sew and find that it usually makes my projects a little cheeper (only a couple of bucks, but you don't have to pay extra for shipping!). However, if you plan on a lycra bodysuit and don't have any experiance sewing with it, get someone to help you. The nature of the material makes it somewhat difficult to work with if you haven't done it before, since it is slippery and will slide while sewing and cutting if you're not careful. The lycra can ususally be purchased at any fabric store in the two colors usually associated with CATS costumes (black and white). Since my costume will be Mistoffelees, I'm using black material. Those people who are going by the video will note that Misto looks like he has a white unitard that has just been cross-hatched to death. This is probably the truth. I am honestly just too lazy to do that, and I'm also considering that faberic markers run about $3 a pop. Most of the other Jellicles require white as a base color. The material is a little on the pricy side, usually running about $7 or so a yard, depending on the season (more expensive in spring and summer when people are making swimsuits out of it). But it is still cheeper than buying one if you don't mind a little work. The pattern I reccomend is the Kwik*Sew #2108, view B. Hancock Fabric stores usually carry this brand of patterns. The pattern runs about $8, but it really isn't a bad deal considering pattern prices as a whole, and considering that this is a master pattern that you can use for multiple costumes. You will also need one 22 in. zipper. I reccomend the hidden kind, which are harder to see. When sewing, if you do not have a surge-overlock machine, use a zig-zag stich.
It will give you the same strech as a surge machine would.
The shoulder fluffies (in Misto's case, chest fuzzies), I made from yarn. Just knot it in the pattern you want, or you can glue it if you use small enough patches of glue and space them far apart. Some people use fake fur, but I think the yarn looks nicer. But let me warn you, it will take a while to do. It's enough to drive a cat loopy! Might I reccomend Mello Yello for those late nights of sewing? >^_^<