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[mobucks]

No to sound like an ass but I'm almost positive 2-5 are untrue/unnecessary.

When all else fails, there is an option in the equip screen (NOT the Uniform screen) to assign specific armor to your dwarves. Pressing enter with this option highlighted will bring up a list of all items in the fort for that category of armor (helm/boots/gloves/shield/weapon ect) Red highlighted items are have already been assigned to someone's (even the current dwarf) equip list. When assigning specific boots or gloves this is the ONLY time you need to assign BOTH left and right items. ie.

-Steel Left Gauntlet-
=Steel Right Gauntlet=
*Steel High Boot*
-Steel High Boot-
It's the most tedious way of doing it but it guarantees they will wear what they are assigned forever once they put it on unless your remove it from their equip list. I'm not sure if it's necessary but I always leave out the breastplate until the dwarves are all wearing their assigned mail shirt.

I would also recommend looking at the armor and military pages of the wiki.

[Two]

Well I did assign their uniforms through the normal means first, but after a year of training drills they still did not choose to wear the armor that was laying right next to them. The moment I did assign it in the equip screen the instantly run for it and were all equipped properly.

Also tests have shown that copper doesn't seem to be metal according to the uniform screen:
"metal armor" -> nothing happens
"copper armor" -> instantly equip copper armor

[gunpowdertea]

Well, the "reassign the uniform after changing it" is definitely necessary (2b), (2a) is not necessary (at least I never had problems with that). I'm not sure about the "two shoes, socks, gloves" thing. It used to be the case - but not always, not for all forts, players, dwarves. Stupid intermittent Heisenbugs...
I am sure the range is irrelevant, otherwise the Dorfs wouldn't happily run outside to pick up *troll fur socks*...
Item (5) might be true, they do stick to their old rags for a very long time - although it might be my fault and I do not have enough nice new shiny stuff for them to wear (or it is in a bin... yeah, I know...)

[Max™]

I get lots of dorfs with one sock or two socks on one foot if I say "socks", but they wear a sock on each foot if I put socks twice.

My civilian armor experiment worked great. New migrants show up, I disable miners/woodcutters/hunters, set up the new squad, with this uniform:

leather armor
leather leggings
leather low boot
leather low boot
sock
sock
shield
shield

Then I unschedule everything, remove all supplies, and activate long enough for them to gear up, then deactivate. No bad thoughts from the draft, extra survivability in case of random attacks, and no bad thoughts from worn clothing!

Though now I'm picturing a bunch of hairy little men running around dressed like S&M fetishists... which is unfortunate.


I do socks because I still get random cloth and it seems to keep them happier, tracking sock supplies is way easier than full clothing as well.

Oh, regarding exact matches, mail shirt+breastplate never has any problems with me, they always wear both immediately after I activate them. I highly recommend using exact gearing for your main military dorfs, as the civvy uniforms lead to lots of swapping armor as new stuff is produced and the "higher ranking" civvy dorfs will do the "grab the best armor for the slot" stuff, leaving periodic explosions of leather armor laying around.