Yeah I was thinking of trying that. The unitard is pretty skin tight, so it would probably work nicely. I have to cut up some foam today for the gauntlets anyway, so I will see if I can get some muscles going.
With my girlfriend working on the skin suit, my last major hurdles are the feet, hands, and mask. The mask is on its way, and shouldn't take too much work. The hands are "coming along" but I'm not really liking them, so I've got my eyes open for other options. The feet are still a huge problem. I'm going by some Halloween/costume stores this weekend (again) to look for some boot covers that I might be able to make work. If I can't find anything, I might just make some armor to cover my boots and be done with it.
Thanks again everyone for all the ideas and comments!
-pete-