About the making of Varia Suit, here is an excerpt from my interview at Metroid Database [link]
"I used various materials and processes. The arms, hand, legs and body were made with sheets of EVA (craft foam).
My friend Lucas and I shaped it by hand, using EVA in 3 different thicknesses.
The Hand Blaster was all done by me, also in EVA. All finishes and details in low relief, I did with the Dremel.
The helmet and shoulders were made in fiber glass by me and my dad. It was modeled using a motorcycle helmet and two polystyrene balls as bases.
The details were carved in polystyrene and polyurethane.
The painting was done with automotive paint.
Electric part was done with 73 high bright LEDs: 30 green LEDs in the shoulders, 26 green LEDs on the Body and 17 red and orange LEDs on Hand Blaster, powered by 8 AA Batteries and a 3v one.
We also used neon green acrylic on the suit and neon orange acrylic on the Hand Blaster."
Time to accomplish the project: 6 Month