Lunalord, we aren't trying to talk you down on this. And, I seriously believe that if you put your mind to it, you could succeed with a great costume. Though, some of us feel we have a duty to to tell you what the end result could be. You don't want to get sucked into the money pit. Clone armor has a bizarre mix of subtle curves and straight lines along with sharp edges. Paper, especially card stock, doe's not respond well when it comes to circular tweaking. You may get most of the sharp lines, but to get both of these elements to meet where required, well, it's not going to be easy.
On the other hand, if you want to proceed, there are extremely talented individuals here and I most certaintly will help out if I can. I think if you can nail it at 90% accuracy during the assembly phase, you can drive it home on the fiberglass or bondo work, and sanding, you can get a good costume out of it. But, it will be heavy. Good luck bud!