I can't recall where I found them, the RPF maybe, but they were free. I can email you the original file if you like. PM me.
It's not as bad as some people think. Because of the glue I use, UHU Universal contact cement, putting the together goes pretty quick. The shaping is also pretty quick because I do a lot of the roughing while the "bondo" isn't fully cured. It's like an eraser in it's cure and I use a rasp or heavy grit sand paper to take off what I need. I don't know how many hours, but I would estimate it at a few hundred spread out over the next few months. The helmet will take the most time. I already have a partially finished helmet, but it needs more work in correcting it than just making a new one that's much closer.
As for the cost, since I'll be making just about everything as a one-off I'm estimating around 700 euros in all build materials also including the purchase of gloves, boots, belt and under suit. To offset some of the cost, some of the parts I'm making for the blaster & pistol out of aluminum I will offer for sale.
Building suits, props, models and such is what I do.
Thanks for the kind words..
The weight doesn't really concern me that much. It's not going to be a very heavy layup process. I'm going to use epoxy and some light cloth that's used in R/C. If needed I'll reinforce some areas with adequate layers, but if it's not needed, I'll keep it light. I also don't do a "rondo" slush inside the pep. That adds a ton of weight that isn't needed. Before I lay up the epoxy and fiberglass cloth, I drench the pep in cyanoacrylate glue - Super glue. This helps seal the joints from any interaction between the contact cement and the epoxy or resin, and it also makes the pep as hard as plastic. You can still crush it, but it holds it shape very well.
As for the heat, if this were foam, there's a good chance I would overheat real quick. The helmet will have fans and as for the suit, maybe some cooling system for a cool shirt if it's needed. There's another suit I'm working on that I'm considering making out of foam, only because it's going to be fairly bulky and making it out of paper is just too much of a headache.
Meh... I'm not into buying something when I can make it. I'm that kinda person... I like the challenge of building it and figuring out how to do things. Plus, I need this ready by the next AthensCon in December.
Thanks... I have an update coming soon..