Good luck with your project. Just making the helmets, I'd say your deadline is certainly obtainable. If you're trying to do full suits, you may have some issues.
As far as your cost offset to have them pay you back so-to-speak. I'd say do one helmet (your Jorge helmet) and figure what the cost is for you to do that one and go from there. When I did my son's helmet. I think total cost of materials (paper, razor blades(I think I used three on his helmet), hot glue, bondo, smooth cast, fiberglass cloth, padding, visor, magic sculpt, bolts, JB Weld, foam and paint would total about $50 minimum just for that one part. I already had a lot of the materials, but the smooth cast I used was about $87 for a gallon kit that makes two gallons. I wound up using about a half of that gallon kit to reinforce his entire suit.
For height. . . . His size is obviously Ludicrous!!!!!! LOL
When you make your boots, you can always make a thick sole for them out of foam and give yourself a couple inches. LOL!
It's good to know stage make up people. Aging lines and scars aren't too difficult to do though with some practice. Liquid latex or silicone work really well for that. And you have drill before you need to be Jorge, you can always get a fake one.
I have several files for I think all of the members of Noble team. If you have problems finding something, let me know and I'll see what I can dig up for you. Hope this helps and again, good luck on your project. I hope to see some more from you in the future.