Yeah TJ took the approach with the upholstery foam and I'm also currently developing undersuit pieces like this as well for my halo 3 chief. Believe it or not, me and Tanner spent alot of time chatting and I ended testing Leak Seal directly on upholstery foam while he was swamped with other suit work. I shared my results with him, and that's what he ended up using fully on his under suit. Leak Seal sprayed right onto upholstery foam for rubberized texture. He told me he won best in show at Houston too with his new Reach build. It looks fantastic. He game ripped the undersuit and made his own templates for it, perhaps he might share those with us other 405th folk eventually!My SPARTAN-III is T3 and I'm pretty sure that once WandererTJ applies for deployment with his new suit, he'll get it as well. Both of us have taken different approaches to the techsuit. For mine it's a sewn skin tight suit with armoured patches. For Tanners, it's a upholstery foam base with fabric over top.
Both suits cover all the paneling that appear on the in-game models but the two approaches showcase how the 405th is all about problem solving and supporting different building methods.