Crankin, what may help your husband is to order eurocut or procut. My husband definitely needs medium tops to be large enough for his chest and shoulders, but then they are often baggy around the middle. This happened on a lovely PI gavia vest I ordered for him. BUT, I found that if ordering him cycling wear I pay attention to the cut, and order what they call eurocut or procut (he does have a european body, he was born in Portugal and is small boned) they fit perfectly. Also, certain stores cater better to his body type than others, i.e. international male. SO yeh, I guess its hard for guys too, but at least a 32 waist is a 32 waist everywhere (although DH's is actually 31, but they are too hard to find.....), whereas a women's 4 can range from a 0 to an 8 depending on the shop. I have clothes in my closet that all fit me, with size tags ranging from XS-M, and 4-8. I am also often a larger size on top (broad back and busty) than on the bottom, hooray for separates! I have one suit I bought as separates where I got the pant in a 4 and jacket in an 8. But most of the time I am a S/6 which I would call my true size, if there is any such thing.

I hope the alpstars work out for you. They don't look like they would be difficult (as in expensive) to alter. I may still do that, but I'm gonna wear them for a season first. While my weight has been quite stable for more than a year now, I find that very slowly my body has been getting more compact.