The armor is made from foam rubber and glued together with silicon caulk. The helmet shell was made from vacuum-form plastic over a scateboard helmet and then foam rubber glued to that. I'll have to do the Gallant pistol in styrafoam since I'm running up against my deadline. I plan on finishing the leg pieces this week and painting everything with liquid latex and paint this weekend.
Pictures of the costume at this stage and the templates I used are here- http://s1016.photobucket.com/albums/af283/insomniac009/



