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I'm still waiting to receive my custom-order from Dahlal (should be here *any day* - I'm biting my nails), so I can't speak from specific experience. However, I did talk to them at length before I ordered, and they did mention that they sometimes have to harass the manufacturers until they get what you want. They did specifically say that if the costume doesn't fit (not counting weight changes) and they couldn't alter it themselves, they'd get another one from the manufacturer.
Since it sounds distinctly too big (if the "add a size" padding doesn't prevent gaps, it's definitely the Wrong Size), there's a good chance that you'll be getting a new costume, in which case you might be able to get the design changes fixed at the same time.
I'd talk to them, and see what you can work out. My impression is that they want to make us happy. As long as you politely explain why it doesn't work for you as-is (and specifically which features are important to you), I suspect they'll make things right.
As a side note, I would at all costs avoid the "the customer is always right" attitude, at least until it's your last resort. That's pretty true for any interaction, but I'd say it's particularly important in a case like this where there's some question as to whether this is the vendor's responsibility to fix (although from your description, I'd say it is). I've been doing tech support at my university for 7 years, and when someone comes to us with a huffy manner and a sense of entitlement, we do our jobs and get the problem fixed (we're professionals), but when someone is polite, reasonable, and patient, we *bend over backwards* to get them what they need.
From your previous message, you don't sound like the huffy or self-entitled type, but I thought I'd mention it. :)
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Nadira Jamal
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