For the armor only...
I have $28.00 in the PVC pipe and $6.00 in the rub-n-buff. I was able to do all of this with one pipe (10' long, 6" in diameter) with some left over.
So the answer is $34.00 I guess. The biggest reason I chose to do my own armor, other than the cost is because I am 6'6" tall and having buit three clones and a Darth Vader, I can assure you that if anyone has armor to fit someone 6'6" tall that it is going to be scarce. My pet peeve is having armor too small. So I made my own to make sure it would fit properly...
Other items to consider... I wanted a heat gun to get the armor exactly like I wanted it. The cost for that was $22.00. The only other items I used were bondo on the knees as well as about $3.00 worth of doo dads from a local hardware store to make the darts, a little bit of bondo and small pieces of ABS for the detail on the backplate, sandpaper, wax paper (sat the PVC on it when I put it in the oven), and a few cans of primer and I think that's about it...
I used a jigsaw to cut the pattern out of the pipe. It worked fantastic. If you don't have one... borrow one to do this. I did use a Dremel for some of the smaller work too.
Hope this helps some.