It's not as difficult as one should think; of course, for a person who would try it on for the first time it might be a bit overwhelming - but once you get used to it, it's got pretty nice weight distribution. The legs offer better movement than our smaller Dark Angel marine for some odd reason
I've seen you around on Youtube. Imperial Fist Terminator?
I'm looking to make my own assault marine armor, based on my character's appearance in the PS3 multiplayer. Any advice for a material to make it with? It needs to be durable, but relatively light-weight, because I plan to add a jump pack.
You should head over to our page www.facebook.com/rosesandboltshells We have a few tutorials and MANY WIP pictures. One of our cosplay friends from the UK made a Blood Angel Assault Marine; you could check that out, look up Render and Spectar Props and Cosplay.
If you are 'sculpting' I would not recommend foam. If you want to go the hard but 'original' route, you can cut out wood shapes and sand it - then vacuform them, to have plastic copies. You could also work with clay of course, but 'sculpting' foam, is not possible as such. All you can do is cut it to shape or dremel it. You can still get good results with these techniques though
My older Imperial Fists Marine was scratchbuilt without templates - whereas my newer Dark Angel is built with templates as reference. All with foam, bits and what I had lying around. Again, primarily EVA foam, craft foam etc. Scratchbuilding today, is a unique process - but it is also slow, much more difficult and to a certain degree not as accurate as the templated versions. I used to be pro-scratchbuild, untill I had a go with the templates and learnt how easy and less material/time/mind consuming it is.
I also have a helmet tutorial on RnB, which is a good starting point. Good luck!