Hey One End!... Cool build!
I don't know if this was addressed earlier in the thread...
Where did you get the foam sheets for your son's armor?
How did the painted armor hold up?
How did you shape it? Did it retain its shape?
How did you attatch it to the suit?
I'm going to start a Jango for my 10 year old and want something that can flex. He plans to wear it at CV and to school on Halloween. So I want it to be soft and somewhat pliable.