I think it's pretty common overall. Even if the actor looks good standing there on set in something resembling the costume, they still can't get what they want in the action shots, with a lot of movement, etc.
On-set photos of the costumes also tend to not look that great, and that is often because the final look will not really be implemented until post-production.
I wouldn't be able to cite all of the examples, as I don't pay very close attention to the effects side of things, but the topic comes up quite a bit.