DONE! Finally.
Finished! And just in the nick of time too. Finally finished all the strapping and fitting at about 4:30pm, just in time for the trick or treating.
Took me about 7 weeks to build, and during those 7 weeks, I've spent M-F in Las Vegas NV, Madison WI, Wilkes-Barre(x2) PA, and Hartford CT. Been home for about 24 hours each weekend, cranked out some work on the costume each time, then shipped it up to my Sis's house in CT, and had a few 2am nights working on it to get it done. I'm amazed it fit him almost perfectly considering how I built it solely off of measurements I had my sister made, and built the majority of it over 1000 miles away.
I would especially like to send out thanks to EvilFX and Volpin for posting their build processes, as that greatly helped and inspired my build. I learned a lot, and hopefully my build quality and attention to detail on my next build.
Phew.
I think I'll take a week off then start on my nephews next halloween costume so this time I can take my sweet time.
Incidentally he said next year he want's to be a HALO Master Chief.
Attached are some pics of my nephew wearing it...and showing us his war face.
Happy Halloween everyone!