@CrimsonAether - Rather then quote all that, I'm going to write like this~
I know your right, they didn't want to be bothered with helping me out due to time/lazy/money/ect. Which, I guess i can understand, But most of them were rather nasty about how they went about telling me no.
Edit: I've watched TheHeroTutorials, both the paper and resin tutorial and the foam versions from Pepakura files. These are my thoughts both methods, that can be applied to both Tiger and Bunny's suits.
The white and colored parts of their suits, (green and pink respectively), I'd opt for the paper w/resin and fiberglass method. These being large, stiff areas of the suit, including the large black pieces that make up tiger's arms. Now, I also plan on having a black spandex (or some stretchy black material) as the base of my suit. The black areas on the torso, back of the legs, these high motion, lots of bending areas, I'd opt for the foam method, allowing easy movement with little to no wear and tear. I had noted in his foam versions of the tutorials, that the method didn't come 'clean' as nicely as the resin and paper version. There were small gaps and stuff, which, wouldn't be seen in the black areas w/ a black spandex suit underneath. These are my thoughts, a hybrid of the two processes, let me know what you think.
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I do not have any 3-d Modeling program nor a registered version of Pekakura yet. The modeling is a bit beyond me technical wise. I'd have to take a class to be able to model those kind of complicated things. If you'd be willing to share your model of Barnaby's suit (I still prefer to call him Bunny) i'd be grateful. I watched the unfolding tutorial you linked as well, and can totally manage that. Just working with the 3D model itself is a bit beyond my skill level, but hopefully I can manage to take it apart into suitable pieces with that blender program. It's my first making something of the Mecha variety, but I'm so excited to try something new and learn. It's part of the enjoyment of cosplaying.
Slightly off topic, but still on the topic of T&B, originally i'd wanted to make Tiger's suit, but a look at his build, wider chest, more manly, I decided Bunny would be a better shape for a smaller person like me. So I really look forward to seeing Tiger done. Do it for me who is much to small to cosplay him!