I made this HEV suit costume for Halloween and a pumpkin chopping festival my dojo had.

It took me a month to make it. Its made out of a closed cell rubber foam called Cross-linked polyethylene. constructing it, i first made a full size paper craft version of the suit based on the 3d model from the game, i then cut that apart to use as a template for the foam. Then glued it together with contact cement, which works awesome, but it smells bad. After that i put a coat of plasti dip spray then spray paint on top of that.

There was a sort film called enter the freeman ( http://youtu.be/NvgEx1g9dW4 ) and they posted a blog about how they made thier HEV suit ( http://www.ianjamesduncan.com/2012/08/14/how-we-made-the-hev-suit/ ) i followed this as a guide on making mine.

Here are some more photos of the costume finished:

http://imgur.com/ffksd

http://imgur.com/yCjX6

http://imgur.com/mYDJE

here are some WIP photos of the costume:

https://dl.dropbox.com/u/1233357/HalfLife/HEVSuit/PHOTOS/2012-10-24%2020.20.05.jpg

https://dl.dropbox.com/u/1233357/HalfLife/HEVSuit/PHOTOS/2012-10-25%2016.55.35.jpg

https://dl.dropbox.com/u/1233357/HalfLife/HEVSuit/PHOTOS/2012-10-26%2021.14.01.jpg