Earlier this year I found Rainbow Dash's Ultra thread and went to work. I also had files made by Satchmo III and Flying Squirrel, so I figured I had plenty of material to choose from. So using Dash's file I unfolded I began with the left shoulder. It is quite large. The pep part is 19" top to bottom. and I definately do not have the bicep muscle to fill up the space. So here are a few pictures of the pep/foam shoulder armor.
For the foam underarmor I just cut out the pieces (minus flaps) I thought were important and made them work. I also left a space open on the backside so resin can be poured in to coat the inside. I will probably cut a larger access to the inside so I can put down some mat in the resin. Also, after reading up on Predator costume creation on the Hunters Lair.com, I will probably go with an Incredible Hulk costume for the undersuit. Should help fill up the space. I also finished the Ultra helmet. It's pretty cool.
Here are a few more for size comparison.
There is alot more to do... hope I can stick it out.