after thinking about it, yeah, im still gonna do it in metal, but probably just the helmet, and maybe the shoes and the gloves, and other smallish things. i think for wieght and ease of construction, the rest would have to be fiberglass
as for smothing it out, i plan on using some elbow grease and bondo (aka metal halmmers an d dollys) and to make the bends, im going to do a cardstock pepakura, and then eyeball the metal off of that
and alot of cars are still made of steel