A big thanks to Juice, Stealth, and Shades for their posts and videos! I followed their threads for many months!
This was my first pep build and I decided to go with the EVA foam and hot glue (seemed easy enough). Overall I am extremely pleased with the product.
Though you can't tell from the pictures (outdoor shots), the eyes and arc reactor light up, mini gun spins, and both arm guns have flashing lights controlled by triggers hidden in the forearms. Each gun can fire individually or in any combination thanks to a custom circuit board and sound effects. And for icing on the cake it plays "Back in Black" and "Shoot to Thrill". I will try to get some videos on YouTube up of it all working.
The photos below was taken at the Marvel shoot at this year's Dragon*Con in Atlanta.