foam is easy for this, its pretty geometric, and you cut the foam and push the shapes forward, but not all the way out and hot glue. I will repost some pics and maybe a little quick tutorial tonight.
Best part about this project is that you can make another copy, paint the raised portions purple, and suddenly you're a member of the Alliance Military from Firefly/Serenity...
The Undersuit is a black t ****. You could mod a pair of grey pants with out to much trouble. But the pants are a heavy nylon fabric, exactly what US military issue duffle bags are made out of.
The pants and original jackets were largely cordura nylon, which
is rubber backed and why those suits don't breath. they're great
looking but tough to wear.
I made all the parts in sketch up, was having a tough time with pep due to edges and end points. I need to go through them and zoom clear in and get everything on necking right.