I'm going to be making profound armor as my costume for Runefest.
I have a 4x8 3mm sheet of Sintra plastic which I can heat and mould into the armor. Once I have the shape I want, I will prime and sand it with a plastic primer in order to make it smooth and then I'll use rub n' buff to make it look metallic and the color of profound. After that I'll attach it to some sportswear(a hockey top and some shinguards and armguards) using industrial strength velcro.
Screenshots of Profound Armor ingame:
Thanks to the following videos for help:
-Nearly exactly what I plan on doing with the heat gun and rub n' buff.
-For the idea to make cardboard moulds to get the shape right
-For examples of how Sintra works when it's hot
4x8 3mm Sheet of Black Sintra PVC Foam
Gold Leaf + Copper Rub n' Buff
6 feet by two inches of industrial strength velcro
Total Cost of Materials: ~170$
Also take a look at JoshHayes16 / C Strife 16 x's videos of his primal armor costume for RF