Well I got some test fit pics I will share.
I guess I should have explained a little better what everything is made of.
The belt buckle is made of 5 peices of steel. (My other hobby is Jeeps, building them, restoring them, etc.) so I drew what I wanted on my computer printed it out and then made the separate pieces with the drill press, mill, hole saw, torches and welder. Then primed it with a self etch primer, then applied the finished coats after masking.
The belt and it's pouches are all made from leather. I used Tooling sides for the pouches with jean button closures and riveted together. Again I made paper templates first and transferred it to the leather. The leather is fastened together with chicago screws and can be taken apart to be repaired or altered very easily. It is finished with acrylic paint.
The mask, knee and elbow pads are made of craft foam 3/16" sheets and painted with acrylic to match. with velcro closures. The mask I heat formed with a hair dryer to a face form and ran another rib of foam around the edge of the upper portion to stiffen in as well as accept the elastic band so you wouldn't see it.
I had the suit made. the wig needs to be trimmed to look appropriate still but shows some pretty good result. The pics are kind of stoic but was more interested in getting shots of the whole getup not necessarily character pose shots.