Ok this was my process. I don’t necessarily believe that this was the bast way to do it. It changed as the project progressed. Then when we made the next two episodes and I changed a lot.
Planning
I read online a lot about how people had made cardboard versions of the HEV suit that they had then applied a material like bondo or fiberglass to it and then painted it. This was my first approach as I had had some small amount of experience using fiberglass and resin so it seemed like a place to start.