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!
Armor Tutorial (great tips & ideas for making lightweight cosplay armor, and some links to sites that provide armor patterns.)
How to make duct tape/foam weapons.
Cool swords made from foam core
How to make light-weight wings
How to make a Cosplay Sword 1 by ~Eressea-sama on deviantART
Witchblade Arm armor Tutorial
How to make a Cosplay Sword 2
Making armour - link to video tutorial from this page.
How to make a Cosplay Sword 3 by *Eressea-sama on deviantART