I finished the costume last Wednesday, finished painting Thursday, and Friday was trick or treating at my husband's workplace. It held up really well and got rave reviews

I ended up not doing a 'wired' bodysuit, custom gloves, or using the shoe pattern. He has on a black long sleeved top and black (girl) leggings, and I had my husband do the shoes, which he just contact cemented some 1/8" foam over a pair of puppy-chewed sneakers. I also left the back of the torso piece open, because otherwise it was too big of a hassle for him to don/doff the piece. I attached straps from the upper arms to the torso, and also put straps on the thigh pieces. The thigh straps have a loop at the top, which attaches to a belt worn under his shirt, because his legs are like little pipe cleaners and if I made the thigh fit, he wouldn't be able to get his foot into it.
I did end up caulking after Plasti Dip. For the Dip, I did 1 coat brushed on, and two coats sprayed, then caulking, then spray paint.
I cannot recommend the EVA floor mats from Sam's Club, even though they're quite cost effective at first glance (if you're in a rush and don't have a Harbor Freight). They were horrible to sand, and tough to work with.
Picture from trick or treating Friday -
/ETA - the gloves were from Amazon, and were Optimus Prime gloves.