The first thought that came into my mind was Boba Fett- the notorious bounty hunter from Star Wars. In costuming circles, Fett is considered to be one of the most difficult, time consuming and expensive costumes there is for a Star Wars character and a lot of people will say that a decent looking Fett costume can't be made inexpensively. I'd like to thank each and every member of The Dented Helmet- the best Boba Fett costume resource for all their help, advice, templates and reference material! Without these guys this never would have happened.
Here's how I made my Fett costume on a limited budget and in a short period of time.
Step 1: Materials
two to three large sheets of cardboard- the sheets I used are called newspaper board (about 1/16" thick and measure 30" x 40") It's available at craft stores and picture framing shops.
hot glue gun with lots of glue
blue foam board (a section of 2x4 scrap lumber will also work)
sheet plastic- I used 1/8" thick Sintra for the armor (available from plastics suppliers and sign shops) and regular styrene ( for sale signs) for the jetpack missile
cotton/canvas dropcloth- available at Home Depot for $10
cotton clothsline- 40ft. or so, about 1/4" diameter
belt buckle (any kind will do but the plastic click lock kind work pretty well)
flight suit- grey is preferred but I had a tan one on hand
lightweight spackling paste
small can of Minwax Polycrylic sealer
aluminum soda cans (four of them)
dark green fabric dye
dark tinted plastic for the helemt visor
spray paint- one can of the following: white, red, olive green, burgundy, black, blue, silver, yellow
There are also several templates that you'll need. This have been graciously provided by Alan (Wizard of Flight) of The Dented Helmet board. All of these templates can be also be scaled down so that a children's costume can be constructed.
Armor templates are here- they are in zip format and they come in three different sizes: http://www.thedentedhelmet.com/forums/showthread.php?t=7825&highlight=armor+templates
Knee templates are here: http://www.thedentedhelmet.com/forums/showthread.php?t=9337&highlight=armor+templates
Jetpack templates are below.