Check out my post at the bottom of the first page. It might give you some ideas.I didn't read all the replies so I don't know if anybody has mentioned this.
I wanted to make ODST armour for paintball for a while. Instead of making each piece individually, why not just vacuum form the pieces, fiberglass and cover the inside with foamies. Obviously, the costume would probably get ruined but I only wanted to make a helmet (over the original paintball helmet ), chest and accessories, shoulders, gaunlets and hip pads so It's easy to run around in. I'll make a test video one day when I get my ODST base models done.
I'd like it mostly for the costume contests they host here during the summer games.