Hey, im about to attempt to make a BB cosplay outfit, and im having considerable planning issues cause ive no idea what to make most of it out if, what did you use predominantly? Cause all i can think of is aluminium structure wires and Balsa wood, and possibly carved foam for some parts but ide rather not use foam cause im not sure its durable enough.
You need to get EVA foam. It is lightweight and is very durable. Also you can use polyethylene foam. Stay away from Styrofoam, it's too brittle. Get a hold of some vinyl sticker sheets to cover the foam.