Anybody have experience doing Kuroko? Will a black background and black body suit suffice? I assume lighting will be critical but has anyone done a live show in this style?

It has been a long time but yes I've used this method for puppetry. Make sure your blacks match. Yep believe it or not there are different shades of black. There is a fabric called Duvateen or Duvatyne that is used in theater to make black drapes. It is a good choice for your background and you can make your suite out of it if you want. Some fabrics reflect light even when black and this one absourbes it. That is what you are looking for. Velvet normally absorbs light also but it can get expensive.

Thanks.  I was considering a tinsel curtain as well, but believe the background motion would be distracting.

Amazon sells body suits (I have a green and purple one) but wasn't sure how well they would work in shadow play.

For now, all my projects will be strictly on video but may wish to do a live show if I discovered the right puppet character.

Similar concepts are used in black light shows. Lighting not so critical though. with black light you just make sure that that light isn't too intense and try to make the black suit as close to the same shade and texture of the back ground as possible o it creates a ghosting effect as the performers move.

I put a bolt of Duvateen on my  Amazon wish list.  I'm thinking of a half circle set with the curve in the back.  I would like to use PVC in the construction so that it can breakdown/setup quickly, if it doesn't take away from the light absorption. A hard set would be nicer but harder to move. If I build one it will be used in the Philippines.

What about the body suit? Should it be form fitting like a green suit?  A Google search of Kuroko showed the guys with sacks on their heads (non-form fitting). 

No the body suits don't have to be form fitting.