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I have looked everywhere, and I have not found any fluff reason for some Black Templars having tabards, while others do not. I was just wondering if anyone knew the reasons why?

Maybe there is none ?
Most or all of the swordbretheren in power armor seem to have them.
Could be a veteran specific thing then.

Or just an option to get that crusader/medieval knight look and feel....

Everybody knows you can't have a proper monastic-martial order without the tabards. Why do you think the shaolin never managed to conquer the world?

It's probably similiar to the Word Bearers whose tabards represent superior rank from the common soldier and veteran status.

Well since the Black Templars are based off the Templars (of the crusades) and other crusader knights like the Hospitalers. The Tabard just meant rank, the squires and lower knights had to earn the right to bear the Heraldry on a tabard. And enemies knew that the tabard was a symbol of the best warriors and there had been cases that knights rode up with their tabards on and whole armies fled thats right WHOLE ARMIES (these guys in the tabards were the best warriors of the day) so I would think the tabard means rank and a status symbol of the warriors prowess in battle as they did in the 1100's.