(Halo 4 armor build progress) Newb question about foam thickness

Progress update: the build is coming along and I think I'll finish in time for Halloween with time to spare to try to get some electronics installed: helmet fans, voice amplifier, hearing amplifier, and maybe even some lighting. I was thinking of trying to add a setup with some lights on the armor that glowed a steady blue but when I press a button a speaker plays the shield break sound effect and then the shield recharge effect, with the blue light changing to a flashing red light and back to blue when the sheilds recharge. I found some kits for the sound effects but am unsure how to get the led lights to sync with the sound effect, so we will see.

Photo dump including a fitting with what I have built so far, I apologize for the quality of some of the pictures as using a phone with gloves and a helmet I'd hard so I accidentally took some in portrait mode

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Getting into the final stretch, and I think I have decided to use my second torso chest/back build instead of the first I posted pictures with about. The problem is neither fit quite right. The first smaller one is a little narrow and way too short but fits well around the lower part , hugging the ribcage right and with a good amount of space between the chest and back. The second larger one is long enough, extending farther down my chest/stomach and sits better on my shoulders but has way too much space in the chest and is loose around my ribs and lower torso. I'm just too long/tall and have fairly broad shoulders and larger traps. I hope between building out the undersuit and some strategic padding I can make it fit well....

I have everything built mostly, I need to put the butt pad, hip peices, and cod peice together into a belt and strap it, do a little padding for fit, finish sealing and painting the torso and belt, and finish the undersuit which I'm still figuring out exactly how I want to do. And detail painting. But it's coming together.

Pic dump.

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Ok finally got the torso figured out, it might be a little too big still but with either a strategically worn bullet proof vest under the skin suit or after I finish the spine for the undersuit it fills out and may be close enough to work . The only thing is the shoulder pads look too small now next to the larger torso. So I might remake them if I have time. But I have the undersuit shoulders done, I just need to attach them in a way that doesn't have them tear off anytime I raise my arms. Suggestions welcome for that. And I have to figure out the spube build since there isn't any foam converted pep files. And finish painting....ok I still got alot of work to do lol .
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Ok I guess I should really kinda wrap this up so het is the last build picture dump.

Had to figure out the spine myself since there is no good pep files that I could find for it.
 

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The finished (ish, I still want to complete the undersuit and maybe install some lights and speakers for sound effects) suit was an amazing success. All the boys were losing their minds, the ladies for the most part were excited to see a "transformer" and so many people wanted pictures I couldn't keep track of them or really get a chance to breathe. It was so much fun and honestly very rewarding to see so many people enjoying the suit. I also got 3 chances to take out the suit over Halloween with a survivor 47 costume watch party and 2 costume contests. I placed 2nd in on (losing to a regular at the bar where it was held with him being dressed up in drag wearing oversized inflatable breasts and butt. He's a friend so it's ok) winning $400 and 1st on Halloween night winning $500. I kinda felt bad since the other costumes didn't really have a chance. But people loved it and we all had soooo much fun, I'm trying to figure out places to wear it
 

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