While I wait for my gloves to arrive, I finally bought the proper McCalls patterns for my inner / outer robes. Right now, in the U.S., the pattern used for the inner robe (McCall's 2060) is on sale for $1.99 (usually $11.99) http://hancockfabrics.com/search?q=mccalls%202060

They only have a few left in stock at that price. Figured I'd pass it along in case more were looking for the pattern for inner robes.
I also purchased the outer robe pattern - McCall's Evening Gown / Cape Pattern (McCalls Cape Pattern 2810) that I found on eBay for the great price of $8.00 + free shipping. This pattern can be found for $15 and up. I lucked out and found an unused / new pattern for a great price. This pattern I think needs some slight mods to it but I will document all of that when my wife begins to sew it.

Now to purchase the fabric, which I have found a coupon for for my local fabric store. Crossing fingers they have the proper amount needed for the robes.
Another question I have...my usual supplier for blower fans doesn't carry the 12v fans right now. Where do you guys source yours from? I'm looking for a good deal so I can make my fan system for the Royal Guard to hang from my next with the hoses going up into the helmet