Alphonse is constructed of an aluminum base covered over with wonderflex (4 whole sheets, to be exact). He is held together with LOTS of pop-rivets and washers, elastic (for better maneuverability) and is painted with 2 layers of gesso, then sanded, then two layers of (color-matched) latex house-paint. The breastplate also has a layer of bondo on it for structural stability. The blood-seal is drawn in marker since apparently real blood doesn't stick to aluminum (yes, I DID try,) the flamel on the shoulder is hand-painted with no pattern or stencil in acrylic, and the "tail" on the helm is real horse-hair (donated unwillingly by my friend Kylah's horse "Stitch.") The straps on the sides are real leather, and two of the side straps are snap-ons for removal and placing of kittens.
Alphonse was 7 feet tall when worn, and the model was Haldan Smith. He wore the costume all day on Saturday and assisted in the construction.