Plans for the build:
The inner structure will be made of flex-foam and an exo (endo?) skeletal frame. The skin will be made of Masking latex with venting stations under the armor. Armor will be smooth-cast 300 with working vents, led's, and fans. I also plan to include a voice amplifier, to make it sound like the elite is talking, and probably a bikers water-bag to stay hydrated. It's gonna be a long intense build. The difficult parts will be the animatronics around the eye's and to control the upper lip and mandible. As for the teeth I recently got with Joe to purchase a Coyote skull. I am planning on molding the upper and lower jaws/ teeth. After a lot of clean-up work and modification this should be perfect for the Elite's teeth, and jaw structure (Side note: this concept was "borrowed" from a guy who did something similar to make Were-wolf teeth). As for hardening the plaster, rondo soaks into and bonds with plaster very well. Just to clear the air, this is not gonna be a fast project. I am looking at making a Movie grade elite, so this may take me several months to years to fully finish. On the brighter side the "Statue" part should be done fairly quick as this process has drastically cut down my working time.
Yes I am planning to mold him in parts, and will be making multiple copies to work from as well as pass around.