Paper, resin, fiberglass, bondo, glazing putty, lots of filler primer, and Krylon special purpose metallics. And some craft foam. And my hair goes up. And I'm too tired to write anything more coherent about this costume.
Edit: Let's try that again from the top.
ARMOR: Most pieces are heavy paper covered in resin and bondo and reinforced from the back with fiberglass. Patterns were drafted by hand. I used craft foam sealed with Plastidip for some of the smaller plates (fingers, around my ankles, those little curved bits above the fauld, etc). The torso armor was made with fiberglass over a plaster cast of my chest, after many failed attempts at flat patterning it.
All the designs are recessed. On the paper pieces this involved cutting out the design, adding a spacer, and then adding a backing: on the chest piece I built the walls of the design up in Milliput and then filled around them with epoxy.
WIG: Short layered wig + extensions from EpicCosplay in butterscotch blonde. Fail wig is fail. It's really small (I had to get an undercut to keep my hair from showing, d'oh), the wig and extensions they sent me didn't match, and after two emails they stopped trying to fix the problem for me, I'm still mad about that >_> Wefts were unstitched and resewn going in the other direction to make the hair go up, and extra wefts from the extensions sewn into the back to thicken it up. I then sewed tulle to the front hairline and ventilated hair onto it. The lace is stuck down with toupee tape: unlike spirit gum, it doesn't burn my flesh.
MAKEUP: Ahahahah oh god my eyebrows suck and I cannot cover them up and I did not have the courage to shave them off entirely moving right along
CLOTHES: I made pants, tunic, and detachable collar out of navy blue cotton shirting to wear underneath the armor. It's all french-seamed and fancy because the sewing machine I was using is an ancient beast from the days before zigzag stitch. There's a pocket over my chest to hold an icepack.
Friday Runner-up Journeyman, Otakon 2012