Tried making an Orion with the new costume pieces since S2, and with the standard Klingon gear, and each time got the character creation failed message. I've only seen one other post on this, so I'm wondering is this real bug, or just something in the game that has not been achieved yet?
So back to the OP... I was able to make 4 Orions successfully - two with the default costume options (male and female), and two with S2 costume options (male and female), albeit the last two costumes were generated by hitting the "randomize" button. No problems getting into the game after submitting application.