While we were doing the mask, we were also covering me in foam and contact cement. The torso was built by using a compression top, sprayed with contact cement and layered up with some old mattress cover foam. We then carved this into shape using long blades, and stuck on more foam where needed to give it the shape.
The heart box was 3D printed, and made hollow to allow a speaker to sit inside it. The wires for this went through the pipe, into the shoulder, under the arm pit, and terminated at magnetic switches stuck to the abdominal area. These switches would allow a magnet embedded in the gloves to trigger sounds to come from the heart box.
The last layer was a skin made of polyester wadding, this smoothed out a lot of the bumps in the foam. We added on some scraps of fake leather where the exposed skin would be and began the wrapping.
The wrapping was made from black tarpaulin, this was the closest, cheapest alternative to carbon fibre fabric. We first started with the wider sections, attaching them using a mixture of contact cement and superglue. The edges were sealed with a strip of black duct tape on the underside to prevent fraying.
We made the skirt separately, using a strip of EVA foam as the belt, again wrapped in tarp, and the skirt edged with weighted string to make it hang properly.
Once all the wrappings were done, we also created the helmet by casting the eye again, and attaching it to a generic helmet pattern made out of foam, this allowed an alternative head. We printed out some cuation stickers, and attached some fake 3d printed staples, painted up the exposed skin, and the body was done.
The hands were made by attaching 3d printed finger tips to some gardening gloves, extending these with a thin strip of EVA foam, padding it out with more foam round the forearms, covering the fingers and hands in latex, and then adding more wrappings.
The last touch we did was create a breathing tube, this was because despite the holes we were able to make in the mask, the air flow was terrible and restricted the time I could wear it for significantly.