In early 2012, I've started a freehand TDK suit. Had built one of cardboard before; crappy, but the shapes was pretty good under the cape. I've decided to improve, and started to work with EVA foam. By that time, I wasn't RPF member, and made many mistakes.......:facepalm
Now I've decided to share pics of the chest and belt. That's the freehand TDK with EVA foam. Used 4mm for base and 2 mm for details. I resined without PVA layer :facepalm :facepalm... It didn't melt the 4 mm, but damaged the 2 mm foam. I've made legs, boots and forearms also.
In my personal experience, velcro was terrible, unglues all the time. Will change it for buckles. Note that the area under armpit is unglued.
Now that I'm almost finished with my IM suit, I'm thinking about start a TDKR with fabric and EVA. Batman. Again.