She really resembles the description of Kaylee Cousland in the fic 'To Spar With A Sten' which you can read/download from deviantart.com :-) http://korithetramp.deviantart.com/art/To-Spar-with-a-Sten-1-209791401?q=gallery%3ABioWareUnromanceable%2F42317442&qo=10
Pauldrons (shoulder armor) are super cool-looking. With enough leather, time, and some basic tools, I can do this. Steaming and wrapping the leather around cylinders or everyday objects would give them the shape, and the scale look is just an indentation tool.
During long sea journeys, and battles, armor, chainmail, and helmets, did corrode. However, there were numerous methodes to remove the rust again, for instance by soaking the items in hot vinegar, and then polishing them with linseed oil.