I think I know something that might help you out. I was also thinking of making a dinobot costume, but not for some time. I am thinking about using pepakura. It's basically printing out 3d models as paper that you can put together like a puzzle. It's really good to look into.
I highly doubt anyone has a dinobot pep file, but you can always look for similar looking things and use those. There are thousands of helmet pep files that you can mod to look like old Dino-butt. I once used a pep file for a halo helmet and turned it into a G1 prime head.