The patch was custom embroidered by Dave at
www.patchhut.com. I sent him a picture and he did them up. $4 a pair. Very reasonable. I tried printed patches, which yield better detail, but I just don't like the way they look. They look like a picture printed on fabric as opposed to a patch. With the embroidered ones, you lose some detail, but I like the overall effect. You can still tell what it is supposed to be and it looks like a real patch.
The dog tags are just small pieces of brass that I cut out in a hexagon shape and drilled a hole in for the chain, which I bought at Michaels Craft Store.
The pants are from BBI Scar and I modified the belt loops to look more like the screen versions.
The shirt is an OD tank top over a Saturday Toys gray muscle shirt. Looks pretty good even if it is not the right color. The biggest problem is that they both were made for male figures, so they are kind of big on the female body. Same goes for the pants, but that doesn't bother me much because if you watch the series, Starbuck usually wears her pans kinda low anyway.
I'm still working on the BDU jacket. I'm not sure what I want to use for the shoulder patches. I have a couple ideas, but I haven't decided on which material to use yet. When I do, I will post pics of the jacket.
The final piece that I want to add is a belt with holster and a sidearm. This is a major challenge as no one makes a 1/6 scale FN FiveseveN and the earlier model they used in the show is pretty complicated. I started attempting to scratch build one, but kind of petered out. I will probably go back to it someday, but I haven't felt like it for a while.
Anyway, hope that helps.