No...there are no foam sheets on the leg part or boots other than the bone spikes. I carved those out of foam and dipped them in latex.
Go back up and look at the pic of the leg sleeve, you'll see it flat on a board, right? The cotton dipped in latex is perfectly visible there...and the black outline you see it placed on is a sheet of black fleece. The cotton dipped in latex is spread out and bonded to the fleece backing you see there. When it was dry the whole sheet became one big piece...black fleece and all.
No, nothing was done to the boot surface. However the whole foot part is covered so it's never going to pull away or pop off. It's as if it's been dipped in latex and as such is it's own flexible boot shell. Still, the latex grabbed onto it very well...and it's not coming off.
Here's how I'm approaching this build in general...The bottom line is the originals Gene wore were somehow done in a similar fashion. Not exactly this way but along these lines, and I'm sure they faced similar issues and concerns...so I'm trying to not over-think this too much. There's a basic logic here...latex, cotton...stick to base surfaces be it chest, arm and shoulder armor, as well as boots. Latex and Cotton...then more latex and cotton...the more you do, the more this makes sense...and the more you start to see it come to life. Sure, I'm sort of winging it as I go, but some aspects of this build just 'make sense' to me to do them THIS way.
I'm not saying it's right or wrong...and I have no idea exactly how the originals were made, but can only guess that I'm 'sort of' on the right track.
David