C3Po Costume

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UPDATE:
Okay, so I've been making the arms and legs just with tapered tubes of poster board to simplify things. I'll probably make the helmet and chest with the pepakura method though.

I've also been having a lot of trouble putting together the pelvic area so that it withstand stress, movement, and allow me to sit down. Does anybody have any suggestions?
 
Build the pelvis, then mold it using FlexFoamit or whatever the stuff is called. I think Ithica uses it. It's supposed to hold its shape well and bend when you need it to.
 
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