Throwing my hand in the pot, as I've gone Iron Man for this year's Halloween event at work (last year was a UD Replicas TDK suit that was a huge hit).
So, after trying my hand and at foam crafting, and realizing I need way more practice than I had time for, and after I had a massive budget delay in the form of months-late tax returns, IM Nation rescued me by putting together a Mark VII suit for me, minus paint and goodies. So I've stepped up from learning how to work with foam, to learning how to PAINT foam. Given the following variables: Cold and damp weather outside (and the presence of pets indoors), inexperience, and minimal time-frame left, between work and other goings on - I'm pleased with how it's come out so far, for the most part. There are a couple minor things, that had the above issues not been present, would be better. I really could've used another week's worth of prep time, sanding, etc. And better temperatures would make for a much better paint result. But for the most part, I'm happy, and I'm sure it'll be a hit with the kids at work on Tuesday when they come through the center.
Oh, and it goes without saying, I have to spray the silver yet too (though the advantage of grey primer means that if I bombed on getting that last bit sprayed, it's still doable as it. Just isn't as shiny.
The chest arc I have a push-light LED thing from Wal-Mart glued to the backside. I didn't think to light it up for the picture, and I don't know how long three AAA batteries are actually going to last. I might hijack my phone bank and see if that would work better, but not a priority atm. I had a couple smaller lights I was going to cut up for the hands, but I won't have time for that, so I'm just going to glue some white discs to the gloves in the meantime. All that I have left to do, is tidy up the faceplate and add some magnets to allow me to pop it on and off, and to add some supports in the helmet for a snug fit, and then it's all done.
(should also note, I'm not going for complete accuracy as painting goes, so there are some accents I've forgone for the time being)