My husbands Emile costume, took roughly 2 years to complete due to time constraints. Made with a variety of materials including bondo, floor foam, found objects, flex foam, and plastic.
Taken during the D*Con parade 2011.
EDIT: Ahh, the nitpicking begins. We began creating this costume long before the game was released from early concept art. So don't nitpick the time. That's why I said ROUGHLY. EDIT again: I also feel I should add that if you want to learn to make armor, check out the 405th.com for all you need to get started.