Styrofoam wouldn't work with the lights (it may melt them). ^.^'
Here's the link for the LED light kit (read it well): http://www.plasmado.com/pro2.index.php
You may have to find the rest of the parts to complete the lights. Here's the instructions for putting them on: http://www.plasmado.com/pro2.tutorial.php
The only difficult part for me would be figuring out how to built up the helmet for the look (going to bondo over it), and vacuum forming the visor (found a neat little site where you can build your own vacuum former for cheap). Do you know how you will build your shape?
Found this for the Thomas helmet: http://www.youtube.com/watch?v=DxjmQ...eature=related
Even though they built it from scratch, it might give you a few ideas. This is the tutorial for it: http://volpinprops.blogspot.com/2011...mas-final.html
If you need help for the gloves, I have information on that, too.