I've been on this website for a while now. This is my first project submission. I hope to have it completed by Halloween of this year. The helmet is a fiberglass piece I recently acquired.
Here's a reference shot of the character: http://i.imgur.com/qn9SI.jpg
The suit itself will be made out of a one piece Lycra suit. I'll adhere shaped furniture upholstery to it and layer the individual segments with K129 Kevlar. I'll use either Liquid Latex or Urethane to seal it. Color will be added with an airbrush.
I'm using a mannequin with my dimensions as a template to create the suit.
I have a 10 amp personal voice amplifier and voice modulator that will be built into the helmet. There are also plans to open and close the face mask by mechanical or servo controlled means.
I spent most of the day yesterday working out symmetry issues on the helmet:
As you can see, the right eye was heavily recessed. I built the area up with polyester filler, filled most of the lines and cleaned up the mouth and chin area. Does anyone have any ideas on how to make the 'skull' completely round? I've been fighting with high and low spots.
I'm not sure how much I'll be able to update this thread because I don't have a lot of free time. I will answer as many questions about the build as I can and post any milestones.