Hey man love what you're doing with this I found the thread looking for reference pics for my own armor and i have some questions if you don't mind.
1. How thick is the foam you're using and is it all eva foam?
2. What are you using for an adhesive is it hot glue or something else?
3. How hard was it to make the neck flanges to taper out?
Wow! Nice build! This has inspired me to make my own Erebor dwarf armor.
This is Awesome. I decided to build my own, and it its pretty good, however, you've inspired me to build the Gondor fountain guard armor from the RotK : http://owenbarrow.org/wp-admin/network/fountain-guard-6611.jpg
Sounds awesome! Would love to see your progress.