I'm beginning to build a suit for my brother but am having some trouble on which pattern to use, does it matter? I've been looking at one that looks promising, but I was wondering if you had used anything specific. I've been looking into the instructable you posted and want to make the suit as animatronic as yours.
Really you could use just about any pattern. The big trick is to make the suit as rigid as possible if you're going to be cutting it up and making the panels move so you'll need to do some significant fiberglass reinforcement.
Sorry for the late reply! Kids have been sick and my wife was in the hospital, as was my youngest son. Things have been pretty hectic around my house but I'll have new videos up soon and a VERY cool project I'm working on too!