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Do you want a suit that will last opening night and maybe a few days ? Then probably 20-30 dollars for cardboard, tape and some spray paint.

A really nice suit will run anywhere from 1000-2000. Ive spend over 800 allready.
Sounds about right. I already spent close to $400 just on materials alone. And I am looking at spending another $800-$1000 on more molding/casting material. But that is just me.

Probably the least costly is Pepakura and Cardboard Armor. Check out Pepakura and Cardboard Armor section of this forum for details.
Well, you don't need plaster so that will make it cheaper for you.

My Mk V modded pepakura suit is half done/ upper body complete (with LED's undersuit visor the works)

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