It's great to see your process.

How will the pillows be held in place?

Velcro! You can see the strips sewn along the outside of a few of them.

My hyena legs hold the bits in place with a single strip and that never fell out, but I'm going for two per this time for overkill...and may as well do it now when it's easier!

so many pieces..... so much work, no wonder the suits are so expensive!! Looking good

Yeah, I really feel why they charge a LOT more for digi legs!

Yup!

will these pockets be sewn completely closed or will you be able to pull the foam out?

They have zippers in them (not shown in this pic). I think some of the smaller compartments (like the kneecap) which just have a block of foam in them I just sewed closed.

YMMV, but I'm a really sweaty guy and I haven't had any problems with my oldest set of legs. The armpit end of sleeves...THOSE need washing. But the rest has been fine so far, with aggressive drying (I try not to leave them damp any longer than I have to).