I thought this would be a clever costume, since many people recognize him but no one ever seems to cosplay as him. My style is to be a recognizable character that doesn't get enough exposure.
This was the most work I put into a costume on my own. I used a Dark Knight Batman mask as a base. After removing the neck and ears, I created the horns from styrofoam cones, wonderflex, and friendly plastic. The sail is also made from styrofoam and wonderflex. I spray painted the mask, but it took nearly three weeks for the paint to dry on the rubber. I glued two layers of yellow mesh to the inside over the eyeholes.
I ordered the blue spandex from eBay, the red trunks from a speedo website, the gloves from eBay, and the boots from a local costume store where I also got the Batman mask. The white trim on the gloves and boots is white electrical tape. The belt is white elastic material and the logo is two different pieces of foam. I purposely made the "A" off center to pay tribute to Shin Chan's cheesy animation style. I made the vest from scratch. I used two layers of quilt fabric and the white trim is Crayola Model Magic. I plan on remaking it entirely out of fabric so I can move better.
Here's a video of my entry in the Megacon Cosplay Contest.
Judge's Award at Megacon 2009 Cosplay Contest