I’ve already been peeking around the 405th site and two options have come forward - pepakura and foam matts. Pepakura is a papercraft program that takes 3D files and unfolds them to be made from paper. Then you can use fiberglass resin to harden the paper. You can also use the Pepakura patterns to make the armor from foam matts by cutting the matts and using hot glue to stick them together. You can also carve details in the foam with a dremel or even exactos.
Both methods have merits. I’ll probably end up doing a mix of both styles. I’m leaning towards making the helmet and main chest armor with pep and fiberglass and the legs and arms with foam. I’ve got experience with making buckles from the Hit-Girl costume, foam work from the foamie Stormtroopers, and working with fiberglass from the Tusken Raider ‘teeth’.
Depending on how much trouble it is, I can then make HALO Spartan armor for us or even Star Wars Clone Commandos