Whew. Well I marathoned through this thread last night/this morning. I can tell you awesome job, but you know that already... but hell. Still. Awesome job!
Y'know when you're wearing the suit without the helmet, it confirms something I always suspected. Gordon Freeman is Master Chief! I KNEW IT! Hah, but seriously, first thing I thought when I saw you in it.
I have a question though. Well, two. Both related to the expanding foam. First... I don't get why you used it on the helmet. I know there's a reason but I never really saw what it was. You put it in around the visor, then cut the visor free, and I don't really know why.
Second, after you foamed the toe onto your boot, I saw the toe again later and it looked like there was no foam on it at all when you showed an image of the toe-piece off the boot. Does it (the foam) all stay stuck to the boot, or...?
And also, huge props, more than for the armor, for how you detailed everything and kept on top of questions. Stand-up contribution to the community, and that takes a lot more than it does, I think, to make a piece of armor. Hats off.