Dr. Horrible lab coat, and so with much whining, wailing, and gnashing of teeth, I put the above coat together for him. We probably saved $10 by not buying the custom one on eBay. (Unless we count my labor as value added. Then this coat would have cost One Million extra dollars.) I ended up using a chef coat pattern and tweaking it a few different ways. He already had the Haliburton case. Welding gloves: Ace Hardware. Welding goggles: Ebay.
I think he has a great chance of getting into the Evil League of Evil in this getup.