Edit: If you notice the pictures on the right the cosplay looks a bit different. This is because I updated the eyes/helmet to look more accurate/meaner.
This cosplay took me about 3-4 months and 300-500 hours of crafting time. It took so long mostly because I had never worked with cosplay armor crafting and I had to learn by trial and error. This was also only my second non closet cosplay so to say I was a newb when I made this would be putting it lightly, however, through a LOT of time and mistakes I managed to get this bondo monster into a very nice and smooth finish and if you looked close enough you would see how insanely smooth bondo gets when you put a little love into it.
The basic structure of the costume is made out of paper mache, cardboard, craft foam, styrofoam, and a LOT of bondo.
I can't really wear this for more than 20-30 minutes at a time and it takes a very long time to put on because it's very heavy and the velcro system I used to keep everything together isn't very efficient. I plan on replacing the velcro with strong magnets but that's for the future.
If you have any questions about how I made specific parts or pieces feel free to ask, I love helping people with their projects and I would be more than happy to help you work through an armor project of your own. (just don't ask me sewing questions :p)
Also here is a link to my photobucket album that has all of my progress pictures http://s11.photobucket.com/albums/a166/ElvenSpirit/Knightman/
Katsucon 2010 - Best of Novice Division