Design tips for a budget Mandalorian build?

[Takanuva]

I started work on a set of Mandalorian armor using custom made templates, but there's one problem: All I have is pink insulation foam. I was able to cut and bevel it with a hacksaw, and glue the sections together with panel nails and Titebond. It doesn't look terrible, but I need some help with finishing it. I managed to use spray paint to paint the foam, but it melts the foam if held too close while spraying. I'll get some fresh pictures up in the morning when I work on it more, but I thought I should get some guidance before I mess things up even more. I mixed PVA glue and water before sanding it down to seal it for the paint, which worked for the most part. I'm also planning on weathering with some thinned black acrylic paint, to give it that laser burnt and acid-melted look.

I have the collar piece, shoulders, chest, stomach, and shins done. If there's any components like thigh pieces, or gauntlets that are a "MUST HAVE", should I make them? So I have that done, but I still need ideas on a Neo-Crusader style mask (don't want to do a modern style helmet, can't find a good helmet), mounting my armor pieces to a jacket from my old Star Lord build, as well as any details I need to make sure it looks finished. So I have the majority of it done, but finishing and mounting the armor pieces and details is a pain in the rear. I'm hoping to have this done in time for Phoenix Comicon in June, which seems like a reasonable date of completion. Any thoughts?