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Rakgirl, I had a costume bra that was way too big once and I fixed it by actually sewing a smaller bra inside it!
I took a bra that fit me and cut it apart. Discarded everything except the cups and opened up the lining on the costume bra. Then I tried on my costume bra with the other bra cups inside it to see where to position it. Mostly you're trying to get the underwires to fit in the right place. I sewed the top bra edge to the costume bra, put some padding between the bottom half of the bra cup and the bottom of the costume cup and closed the lining back up.
It worked like a dream. My own boobs rested in the inner bra cups like hammocks, all the cleavage was my own, and it was totally secure.
I'm using gel inserts in a too-big bra right now, and I don't like it. They're way too heavy, the neck strap is about to kill me. Hmmm, wonder if I can find an hour of free time and a bra I'm willing to cut up!
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