The suit would turn out to be a crafter's fun project. Bits came from Goodwill, craft stores and found around the house. Hot glue and duct tape were also in high demand. The finished product was unveiled on the 31st of October to much hoopla. The costume went to school on Nov. 3rd for show and tell.
All in all it was a fun project and has inspired us for future Halloween fun.
Step 1: Gauntlets
I cut out the bottoms and a strip up the side to size them to his arms then cut them to length at their wider end. I cut the wrist end to allow his hand to flex properly.
As I had some red duct tape (Heaven knows why) around the house, I decided to cover the gauntlet sleeves in this. It made for a fairly cool and impressive look in a short amount of time. The slit along the side was simply butted together and taped into place before covering with the red tape.
Red, child sized gloves were used for his hands. We originally thought of making small finger and back of hand plates out of plastic but opted for the simple gloves in the end.
The repulsor emitters were the paint cups cut out of a plastic paint palette and hot-glued into place. On the finished version these were covered in thin aluminum sheet (slightly thicker than aluminum foil).