Just my opinions, of course. The ones I didn't respond to, I don't have an answer or suggestion.
2. Should I go with all splinted leather on every piece like the german effigy or go with Stapleton's kit that is more English and thus more up to date with the plate arms and splinted cuisses and greaves. I was told from a saftey point of view I should stay away from splinted arms...any input on that?
From a safety perspective, somebody hitting you hard enough to leave bruises or break bones through splinted or plate is hitting too hard. If you're doing steel combat, even rebated edges will "chew" at the leather if they strike it without grounding out on the steel splints, but it's not going to fail overnight or in a single bout, it would take many years.
3. Leather or fabric CoP? or does it not matter because eventually I will get a surcoat?
Leather will be more expensive; if it's getting covered and you aren't doing living history, doesn't really matter.
4. How historical would it be NOT to wear maile underneath everything? Keith said it can be done and in SCA no one will bust my chops...it would be nice to have some reprieve on expenses as far as armor goes for a little while...if I showed up to DoK this next year would I not be allowed to not dress up if I didnt have chain under the kit?
When you're talking about fighting in plastic armor (SCA) and fighting with imaginary armor that doesn't even reflect what you're wearing, anybody busting your chops over lack of a haubergeon can probably be ignored. As far as Days of Knights, I don't think it would be an issue to not have the mail. If you can find effigies or sources that show it existed without the mail - perfect. If you can't, make sure when people ask about the armor or if you give any impromptu presentations that you mention mail would be worn with the armor. Many people are in-between states of completion with their kits, and as long as you don't try to pass it off as complete and accurate when it isn't, it isn't a terrible offense. The primary goal for DoK is to keep out fairies, dragons, dwarves, sci fi, etc.
5. I have read extensively about voiders for transitional sets and there is no proof AGAINST them, as many transitional kits are based off effigies (there is very little existing armor out there I am told) and voiders and aventail and skirt would trick an effigie into looking like a haubergeon. I ask because...
It's a very loaded topic. Even some accounts of voiders in later period harness aren't always constant. There is artwork showing that late period italian armor, when it was "full plate", had a double-layer fauld; some speculation on it actually being a fauld with a haubergeon worn over it. Some of the later period italian armor actually wears the sleeves of the haubergeon over top of the upper arm harness, which means it cannot be voiders. The best we can do is make an educated guess at what's hidden from us in pictures, by trying to extrapolate from other sources. So I would say, buy whichever, as there's no hard evidence one way or the other.
6. Gambesons...I seriously contemplating the revival.us gambeson and I am told that it might not work so good with riveted mail haubergeon with the cloth buttons and it being so thin. The kit Matt has quoted me is about $1300 shipped for a Helm with a peferrated sheet under the eyes for HEMA/WMA, shoulders, rerebraces, elbows, vambraces, cuisses, knee cops (fluted like the german effigy), and greaves...all of it splinted. That plus the gambeson and some period shows put me at like $1500...The wife is not going to go for that easily and putting 250-350 on a gambeson and 500 more on riveted wedged flat mail....it isn't going to happen. So I was thinking paying the 100 bucks for the revival.us gambeson and transition it into HEMA once I have had time to save up and get the gambeson and mail.
The mail can catch on the buttons a bit but once you have it on, it should be of minimal issue. I've had my haubergeon on over cloth button gambeson and aside from actively getting into it, didn't have any other trouble. I haven't worn it for 10 hours, only around the house, but it's a minor concern. You can always take the cloth buttons off and do a spiral lace conversion - it's just cutting off the buttons and sewing holes. The most important aspect of a gambeson should be in the arms/fitment, rather than how it stays closed.
You can always start with a cheaper gambeson and upgrade later. They are somewhat of a "wear and tear" item, you probably won't have it forever.
You can also pick up the mail down the road. No need to buy everything all at once. Most people don't. Have it on the radar as a planned kit upgrade, but start with the basics and work from there.
