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I haven't done a lot of work with craft foam, but it seems a much easier route than actual leather.. How easy was it to move in? Were you able to sit down? (Thinking about the wearability of craft foam armor.) I saw that you mentioned buckles and velcro - how difficult did it end up being to get in/out of?
What I'm doing now is recreating a more lore-friendly version in foam as a template (since I can't get the old one apart) that will have fully articulated joints for range of motion. And with this template, I intend to make it out of leather this summer because I love this armour so much, and it'd be kick ass.
I'll be putting pictures/references of my template up when I finish it so that people can have a better idea of how it all fits together.
Good luck with yours and feel free to ask me any questions you have.
Most of my progress is being posted on my blog if you want to see more of my step by step and other photo angles.
nocturnal-nightingale.tumblr.com
Can't wait to see yours.
-Kat Valkyrie
Feel free to submit this to the group. Since you're a contributor, I don't think I even need to approve it first.