Sorry, going to block comment; Outlaw, and John3d, thank you greatly for your work on the sabers. I blame you both as now I will have to try them!

 

Sandman, I've had this happen too. What I do when setting up the cloth is the usual fit to character, then scale up the cloth piece til' its way bigger than the character (at least large enough that nothing touches the beneath) and drape as usual. It's fixed most of my issues when going to Reality/Lux.

If you've got a screen shot, I can be even more helpful

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