I didn't know the first suit was modeled after circus strongman outfits!  Huh!  Those outfits haven't changed that much!  Still Skimpy with an emblem on the chest.  Who would've thought in 1938 that it would turn out to be so iconic!

His original supersuit with the red pants on the outside was indeed made by Martha Kent from the blankets he was wrapped in when he crash landed on the earth.  He used his heat vision to unravel it and metal from the ship as needles.  Not bad for the day!  Fast forward about 50 years and now his suit is, if I remember, a Kryptonian power suit.  All he had from his childhood was his cape.  He found the suit when he leapt from the earth to Brainiac's ship to stop him miniaturizing Metropolis.  He reprogrammed Brainiac's ship (and Braniac) into his first Fortress of Solitude while calmly stealing the suit!  An incredible story by Grant Morrison, who in my humble opinion, is the greatest writer of comics and especially Superman that I have ever seen and considering Kingdom Come that is a powerful statement.  Most of all I like his hopefulness in a world of dark heroes with masks.  In the Movie the suit was made or produced by his real father which we won't get into now.  The movie had a few flaws, no?  Still, I loved it.

Luckily, Ironman13 and Fuzagi's Hexagon lessons have taught me well about using Extrude so I know exactly what you mean.  Still, in all of the examples you've shown so far I can't see any distortion.  Is the issue the emblem is more or less rigid?  I think the shrink wrap option could take care of your worries.  Anyway, the design of the emblem itself is good!  It looks like it fits the outfit to me though I don't know what would happen when given an action pose.  It's common for Supes to get walloped then come back and win the day.