The abdomen/chest armor was made of foam sandwiched between two layers of duct tape. Duct tape straps (with velcro stapled/glued on) allow it to be strapped to my waist/chest. Since the back is usually covered with the cape, this suffices and allows better breathability than a full suit.
The mask was made out of an old baseball hat. The front was cut off. From inside it, the plastic support piece was removed and reshaped using hairdryer heat into a nosepiece. The hat was covered with duct tape. A shaping rod made from a coathanger was added to give the eyebrows more definition and to give the ears some rigidity.
All images copyright Rob Emery