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But to answer your question about materials.
I am using to a big extend EVA foam and fiberglass and real steel armor.
depends on the suit. - Nemesis is the Vinyl coats and a muscle suit on which I appliead tons of latex to form the open and very musculus arm.
the advantage of EVA foam is that you can cut it - grind the edges easy - dremel structures and textures in it... glue it well with hot glue - and shape it with a hot air gun in any shape..
depending on the the history of the suit - does it receive more or less damage signs..
painting technic ( wash ) is key - in order to create the " used - battle hardened look "
a lot of work - but ever so rewarding when you have kids crying at helloween and adults screaming and running away during airsoft games.
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