I have a full build thread located on the RPF forum here: http://www.therpf.com/f24/sylgians-4...ne-wip-179602/
an another on Obscurus Crusade here: http://obscuruscrusade.com/forum/index.php?topic=1625.0
And you can find it on facebook here: http://www.facebook.com/garysterleystudios
This was my first time working in foam and also my first time working on something so large. The costume stands roughly 7ft tall and requires that I walk on stilts. The hardest part of the whole process was probably the Power Fist (the giant left hand). I designed it in google sketch-up and 3D printed all of the digits myself. It is fully articulated and I am extremely proud of it. Designing everything in 3D was a huge hurdle. I am not a 3D modeler. I have been trying to teach myself the software though, and this is the largest and most complicated thing I have ever designed.
Total cost was roughly $1300 and it took up about 450 hours of fun (aka labor).
Step 1: You are probably too short.
Step 2: Pepakura Patterns and Foam
The foam I used can be found here. You will need 6 sheets 1/2" thick foam, measuring 72"x48" each!
Print out the templates, transfer them to the foam and get cutting! Use a SHARP knife. Replace the blade often or sharpen it as you go. Work clean though. A little care now saves you clean up later.