I haven't looked in on this project for quite a while, good to see your still going forward with it Zap, RL throws in a monkey wrench from time to time keep up the good work.
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Eva foam is a good matterial plus it's very resilient and easy to work with. However no costume is free standing without a frame to support it look on YouTube for duct tape dummy by The Heros Workshop and look up Evil Teds Channel for working with foam also Punished Props good luck I've been...
Haven't been here for a while I come back and see this! One Metalhead to another Right On bro! as one of the Big 4 Metal bands been fortunate to see them in concert