Well, I was thinking of doing a boys of silence for my brother (since ive gotten pretty popular for my Booker cosplay on deviantart and the 2k forums, I figured i would have another character in my upcoming pictures.)
What I would do is have someone make a Pepakura file for it. If you don't know what Pepakura is, It's very easy to just type it in on google and there are TONS of help forums for it!
After that, I would print out the pepakura model, glue it together, fiberglass it, bondo it, and then do all the small details using clay and things of that sort. for the suit, that's just plain and simple sewing.
Hope that helps!