Yes, I've jumped on the foam Ironman band wagon as well, but I'll post about that in my other build thread.
Rondo strength test - YouTube
I made a short little video to show how I might coat my suit, might.
The hesitation come from the sandabilty (If that's not a word, it is now)of the mix I made, very tough going.
You would need to dremel sand edge and corner build ups. That said I just eyeballed the mix, but I think I will be more inclined to try a 70/30 bodyfiller/resin mix next try.
Foam:- Campri Foam Sleeping Mat 2012 - SportsDirect.com
Bodyfiller:-Upol Easy Easy-1 Upol car body filler 3.5ltr tin Easy Sanding - UK Mainland delivery | eBay
Resin:- Polyester casting resin. MBFG.co.uk
Excuse the accent, I'm a Brummie (A person from Birmingham, UK).
The first crack that appears after I dropped it was due in part to a blade cut in the foam.