I'm working on a grunt suit for my neighbor he is about the right size for one (he's 8), next halloween I'm taking him trick-or-treating for fun. When I get started on it I'll post pictures on my profile.
I made one for about $20, Pics of it are in my only album . I'll video tape it and put it on youtube soon.
Mine only took about 2 months to build (But it was cardboard, I built the arms in 2 days... looks good from a distance, but still...