Thanks Marines!
Tom, I don't see why not...Gimme some time to finish this fully before we talk more details. Cool? Thanks brother!
Anyhow, I'm gonna need abit more advice from you on that PR i reworked for my friend. It's now mine and I want to go with a TM body...Muhahahaha. I'll try to pick up one in Oct when I hit Taipei.
DSB, yup, there were 3 of us.

Of course during the plastering, I dragged in another to help.
And just to be very obvious, this will be a wearable costume. :thumbsup We are looking at a few choices for the actual suit construction once it's casted. It may be a full blown latex suit with a few underair cuts to allow movement...or it might just work as a trim and paste onto a divesuit/undersuit. I'll keep you posted.
Now the head will be a different thing altogether...as I'll be casting that out of resin and fiberglass. This was decided as the best so as to allow any 'upgrades' to be made possible inside a 'protective' hard shell and to keep the head nice and firm [that sounded wrong didn't it?! :lol]
As for the weight issue, I know some of you are thinking that with the resin and FG choice but don't worry as i'll be using a coating style method so as to keep the weight down...kinda like our Dr Doom masks.
The headpiece will be secured onto a helmet [again, I will work out the choice of helmet and little details once we get the first cast and see what works best.] and like almost all ALIEN suits now, the wearer's actual head will be at the neck area.
Some pics..
And the aftermath after pulling off the Molds...
Bad news though, a few of the arm molds cracked, so it'll have to be repaired [which can be easily fixed, so no worries there

]...other than that, the rest of the Molds look fine. :cheers
Will keep you posted.
Stay safe,
Tim.