Thanks, everybody! I will cast in fibreglass/resin, then make a leather liner with straps. The outfit will be a one piece. I have heard of some folks doing a two piece, but it just doesn't make sense to me-it seems like an overall.
Yeah, I need to get back to this, for sure. I have many projects on the go right now, but I'll be back to this this week, hopefully. Right now I'm making the USO shield, and just finished Conan's necklace. More on the helmet soon though!