I made my manequin last night. I made two mistakes. One I used the cheapest duct tape I could find. It is so thin it doesn't keep a good shape. I have not stuffed it yet so it may be OK. The second mistake was that I put tube socks on and stretched them as high as they would go. These went on the outside of the long johns. When I got out of the suit the areas of the socks shrunk back down and crinkled the duct tape. Again I hope that with the stuffing I am using it will stretch back out. At worst I can just do my calves again.
I picked up a wired set of flexible LEDs from Auto Zone. I went with blue and although they will not be movie acurate I want the range of visibility that full lenses provide. The led packs are already wired to a battery pack for in-store testing and they come in white, blue, green or red. I may even make it so I can switch them out easily. Red eyes in the dark would be pretty wicked.
If you have the room for fiberglassing and are just quitting because of the toxic fumes then I have to recommend West System Epoxy. It has no smell at all and only needs the temp to be 45 to cure. It is more expensive then fiberglass polyester resin like Bondo brand. I order the fast cure by the gallon form Aircraft Spruce and with delivery it is $130. Epoxy is super slippery and I have to glass things in stages so that pieces dont pull away from their own weight. It is used for airplanes so I think it is good enough for me.