The armor was made from 1/8" sintra. Rob and I had a some good times cutting it out and molding it.
And here we have a completed helmet. I want to point out that a lot of the armor had lines cut into it and lined in black. The chin piece got some silver rub'n'buff to make it look more metallic.
Here is most of the armor put together. We had a few options for the abdominal section, but we decided to use the one from last year. It was still quite good and took a coat or two of paint to match the rest of the costume.
We didn't get too many pics of the upgraded arm cannon, but this shows the new LED system. We took a 3" PVC pipe and wrapped a sintra cone shaped piece around it to get a nice bevel. The inner part of the cannon had the LEDs on it and the cone slipped over. The end of the cannon had a 3" to 2" adapter and a strong LED flashlight in the end. I am looking forward to improving this part even further.
There is a Metroid just to the left of the screen that totally just got blasted.