gilby,
I recently purchased a Raggedy Ann/Andy pattern from Simpicity. the raggedy Ann costume looks fairly comfortable and easy to sew. I would stir clear of one-piece jumper-type outfits. My first clown costume was a jumper. It was really cute, but it had a zipper down the back, and was fairly inconvient, especially if you have a balloon apron, belt, and maybe a jacket over the whole kit and kabboble.
A trip to goodwill would be worth your while for sure, especially for loud pants, vest, etc. Don't be afraid to think out of the box (i.e. look in the women's section for vests and things.)
Have fun,
Miss D.
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