As of now (I'm writing this up a day after Otakuthon 09), this is the project that took me the longer to get through (in term of effort), that was the most challenging and that I'm most proud of :).
The suit is made out of foam - either camping mat foam or craft foam. It hang on a system of strap that I'm really proud of (takes me about 15 min to get in and 10 min to get out of this suit - however, I need a helper since the chest piece and the shoulder really limits the movement of my arms). It's really durable - after one day at the con and a masquerade skit, I only lost 1 bolt... real easy to replace :).
Thanks for looking.
Best in Show - Otakuthon 09 Masquerade