At best as I can tell, this has been a problem for some players for a while now. It occurs if you access the tailor option while in space, through means like promoting BOFFs to active duty, then also trying to alter you captians as well. A ghost or hidden costume slot is created for that captain. These slots are not normally visible through the tailor or costume selection screens while on the ground at ESD or DS9 for instance... they are only visible while accessing the tailor while in space.
The problem with this ghost slot is that it over rides your normally worn costume during in game cutscenes and on the character selection screen if you are in space. Additonallly, this ghost slot has limited options.. it is hard to edit and all costume options available to your captian normally, may not be availble to this slot. This is very irritating if you've made significant alterations to your captain but during the cutscenes and on the character slection screen... the options locked into the ghost slot is what appears.
Examples
Access tailor while at ESD
Access tailor while in space
Character select screen showing wrong costume while in logged out in space
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