Yess another Gears head!
Get some progress pics up when u can! Check out Propcustomz work. I can't stress enough for people to check out his awesome foam build of baird. Pep the helmet. People always seem to look at the helmet first. Put your effort into that. Foam is fantastic for boots, greaves and belt. (good for maneouvrebility). Propcustomz has some templates in his thread.
Get plenty of reference pics! Google, game pics (i took photos whilst i was playing), and Neca toys have some good designs.
Also......
Don't get shot in the head.