I bought an Israeli flak vest clone from a member here a few months back and decided to finally get the thing filled out. An old thread on the subject mentioned using 1/2" padding (thanks Russ!), but since I didn't have any of that I decided to improvise. I had some spare L.L. Bean dog bed padding from my work ("we manufacture those by the way"), so I peeled back the layers until it was about the right thickness, cut it to size, and then wrapped the whole thing in criss-crossing layers of duct tape.
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Less blurry:
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Here you can see the dog bed padding. Nothing special about it, I just happened to have some for free so I went with it.
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The duct tape adds a bit more rigidity and weight to the pads. My fear was that it would look like a winter vest otherwise. Have other folks tried anything like this?
I'll get a full costume photo taken soon!