Why was it ever put in the REQ Packs? When you went trough H1-4, this really felt like a reward. But now...I like this armor but I don't like the fact you have to be in a company to get one and have to wait a year... and then get kicked out because someone just didn't like you but you had way better kill rates then that guy, who was only their for a week.
Shon, will you start a seperate build thread?
Foam might be the right idea. Have no experience with it myself, but seems adequate for this curved, smooth armor design...