I'm being suprised at how easy this is so far; everything is working on the first attempt, without any major backtrack-requiring glitches. It's also not taking very long at all. Which might be a first for me - always seems to take three times as long as I expect, and cost four times as much.

The pink stuff is 1" polyurethane insulating foam. I hated the stuff at first, but now i've got the hang of how to shape it without it crumbling and breaking. It's also very forgiving; if I don't like a part, I just shave it flat, epoxy on a new piece, and then shape that bit.

I don't intend to get too fancy with the body mass - it's just to fill out the costume.