>>10967234
Make sure you buy a good quality high density foam, otherwise, working with it is a mess.

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>>10967234
I did a Gordon Freeman costume a couple of years back as my first real foam project. Sorry for the photo, couldn't find a good one and didn't want to haul it all the way out of the attic.

1. If you have the time, try taking one piece through the whole process (mockup, cut, form, glue, prime, paint) before you start on the rest. You'll learn a lot just from doing one piece, so you can apply that knowledge to the rest of the project.
2. Don't expect everything to fit just because the mockup fit. Leave extra time and materials in case you need to remake a couple of parts. Also don't just try it on before priming and painting, wear it for a few minutes, walk around, pick things up, bend over. etc. My forearm pieces ended up too long, but by the time they were painted it was too late to fix them.
3. Getting good seams is an art. Don't expect your first project to have perfect seams.

Good luck & have fun!