This is my second year making an "epic" Halloween costume. I started work on September 21st 2012 and finished on October 30th.
I based my costume on a uniform from popular video game Mass Effect. It specifically reflects Commander Shepard's non-combat uniform used by default in the opening mission of Mass Effect 3.
That said, I had a few design goals this year which predominantly focused on functionality and robustness. This lead me to select steel reinforced heavy denim, for the armour, finished with a leather-like laminate fabric.
The uniform is 7 pieces: Boots, Pants, Under-shirt, Dress Shirt, Lower-Body Armour, Upper-Body Armour, and Belt.
Out of all this, only the Boots are store bought along with under-shirt (a t-shirt) which I altered to make the Turtle-neck.
For my tutorial, Step 1 contains a step-by-step tutorial on how to create a fabric-sheet metal armour construction. This was my secrete ingredient for this project. If you continue to steps 2 - 8, I give a quick overview for each piece of my uniform.
I hope you can find this information useful in your future construction endeavours!