F.B.
I saw a kid with an awesome one on the subway this weekend. (I guess he was headed to comic-con). His was laminated and taped onto a box. The arms and legs were cardboard (box tubes), sized to his arms/ legs, and covered in duct tape. Only trouble is, once he got the costume on, how was he ever going to get around??? (maybe he could be strapped onto a handtruck and pushed by a parent).
Best,
F. B.