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Ahh I can help with the armor definitely ^^ but as for the dye, just be VERY careful what kind your using, dye will fade given time, the longer you leave the outfit in dye, the darker it will be, this is ideal to making sure the color last and fades out correctly with time. When dying it I'd suggest using like a bucket from home depot to dye it uniformly and then hang it out to dry after its sat and absorbed for the time you deem needed (again longer is definitely better) if it's very sunny out when you go to dry it, it can lighten the color up, if you don't want that hang it over the shower. That can stain tile tho so that's the trade off. Be careful on that end.
As for armor the best movable bet I can make is foam. Having a heat gun and craft foam for quick light armor, if your more willing to work with a knife I'd suggest foam mats that I will link below, they make much more of a flair kind of statement, bigger and more durable but harder to work with to start. For attaching armor, I'd use Velcro. Don't glue anything on your body suit, it'll be hard to clean and it might be a one time thing if you do, if anything just hot glue the Velcro on to attack shoulder pads or knee pads and then have a strap on the item itself for more support after the fact. If you have anymore questions you need me for back and fourth real time things as your working my cosplay Instagram is @shoe_icky_sucky_hara :) hope this helps!!

https://www.amazon.com/BalanceFrom-Puzzle-Exercise-Interlocking-Tiles/dp/B01IDRWPG8/ref=mp_s_a_1_3?ie=UTF8&qid=1550438515&sr=8-3&pi=AC_SX236_SY340_FMwebp_QL65&keywords=foam+mats&dpPl=1&dpID=51IuRBZT1uL&ref=plSrch

I'm making the same costume for my wife. I found flexible pvc spa hose on Amazon. It is rigid enough to hold it's shape, but flexible enough to bend: https://www.amazon.com/Sun2Solar-1%C2%BD-inch-Flexible-Above-Ground-Swimming/dp/B06W2N4Q1T/ref=sr_1_5?keywords=spa+hose&qid=1558119853&s=gateway&sr=8-5

I'm planning to add the "ribs" from her tentacles by using pipe insulation foam around the spa hose, and then shaping it with fine sand paper. Foam insulation is here: https://www.lowes.com/pd/Frost-King-1-in-x-6-ft-Foam-Plumbing-Tubular-Pipe-Insulation/3133247 . I'm still trying to figure out the best way to add that "alien skin" look to the tentacles. I'm looking into silicone molding, but it looks pretty advanced for me.

Good luck!

There's this weighted vest which is approximately $70, but will allow your friend to show of a green/ camo athletic long sleeved shirt underneath it with a heavy weight lifting belt. If you go this route, you can glue some straps to the underneath side of the vest and belt to make the look like they're attached. Then just add in any extra details you see fit.

I would recommend looking around for tactical vests or weighted vests until you find what you feel works best.

Edit: Pricing is different if you want the vest only ($70) it becomes more expensive if you add the weights.

Sorry for the delay, I've been looking around a bit.

If the shape of the mask is just a rounded surface, there's a fairly cheap featureless chrome mask showcased in this video. They bring up painting the masks with transparent paint, so there shouldn't be much issue if you need a specific color.

Another option is vacuforming, but this one would take a bit more work and is more costly. If you don't have a vacuform machine, here is a video for making a simple one, and here is a tutorial for vacuforming a mask (for the shrike skin, funnily enough). There is also a video here for tinting a vacuformed visor if you want a bit more information on that aspect. You can use a number of plastics for vacuforming, but people tend to use PETG plastic for masks and the like because it's clear.

 

I'm unfortunately not too knowledgable when it comes to fabric paint, but I'll help where I can. This website and this video have tutorials for painting on denim using acrylic paints. If you can get glow in the dark acrylics, that method might work for you. There's also this fabric paint, but I can't personally vouch for it since I've never really done any fabric painting. Those seem like good starting points, but I would suggest doing a bit more in-depth research before starting

Eva foam is the best because it takes to paint the best and can be glued the best and all around good to work with but other foam can work well to you can be Eva foam thinker if need be I have found Eva foam at the dollar store before all tho not named as Eva foam here is a few Amazon links for Eva foam. https://www.amazon.ca/Sheets-Craft-Cosplay-Thickness-1-10mm/dp/B07BSWRCQM/ref=mp_s_a_1_8?keywords=eva+foam&qid=1567863867&s=gateway&sprefix=eva+&sr=8-8. https://www.amazon.ca/Time-Crafts-sheet-inches-Black/dp/B0764LX5Q4/ref=mp_s_a_1_7?keywords=eva+foam&qid=1567863867&s=gateway&sprefix=eva+&sr=8-7. These are only a few one on Amazon you should do some searching yourself

I would recomend

https://www.amazon.com/dp/B07HRHDV1T/ref=cm_sw_r_cp_apa_i_kdNoDb1DGMBJ9

Ive used them before and they're pretty good. They're waterproof and can be controlled thru an app. Good luck.

Amazon sells grills. You can either paint the words (food safe paint recommended) or engrave them with a small piece of sandpaper. My friend used the sandpaper method and it didn’t look as good as I’ve seen others do.

There is also a good tutorial here

The jacket looks similar to one of these styles,

Rothco MA-1 Flight Jacket, Gun Metal Grey, L https://www.amazon.com/dp/B015HKBSIA/ref=cm_sw_r_cp_apa_i_8DQEDb090F4RJ

CRYSULLY Mens Zip Up Motorcycle Windbreaker Faux Leather Jacket Unfilled Bomber Jacket Coat Outwear Grey https://www.amazon.com/dp/B07G4TD99C/ref=cm_sw_r_cp_apa_i_WEQEDbRH9ABP8

And the skull mask could be something like this?

WTACTFUL 3D Skeleton Lycra Masks Scary Skull Balaclavas Ghost Headwear Cosply Costume Halloween Party Ski Full Face Mask https://www.amazon.com/dp/B01M4P2ACJ/ref=cm_sw_r_cp_apa_i_sHQEDbT2JDCQ5

Good luck! You'll look great

Jewelers polishing compounds. Something like this: https://www.amazon.com/1-Ounce-Polishing-Compound-Jewelers-Plastic/dp/B00I8Z26GK


If you have a rotary tool with a soft wheel, this will take all of ten minutes to fix. If you're doing it by hand, it'll work as well, just take longer. For a rust spot like that, I'd say the order of operations should be Black, White, Green. The black will get rid of the rust, the white will smooth the area to match it's surroundings (go light on that, you don't want to mess up the grain) and the green will polish it back up and leave a little protection on it so it takes longer to damage later.

We did an Adventure Time Halloween theme!! I was Ice King and wore this: https://smile.amazon.com/gp/aw/d/B00PVU1PWQ?psc=1&ref=ppx_pop_mob_b_asin_title

Edit: yeah I'm also about half a foot shorter than you. 😐