Extremely detailed instructions on making full body casts using plaster and fiberglass and making durable, reusable molds for armor. This is an excellent and thorough tutorial. His armor material is HOT GLUE!
How To Build Your Own HALO Outfit: KAT
How To Build Your Own HALO Outfit: KAT // I'm not into HALO, but I could see this being useful for video game fans and Mecha genre cosplayers making EVA or Jaegar pilot suits.