I used this Buzz Lightyear Costume 2 years ago in Brazil. This costume was made with several rubber parts. We had the job of separating the armor parts, cut and paste the pieces. The concept was pretty simple, but to execute parts so stay equal to the Buzz was more laborious, almost dramatic. When we finished this first step, we joined the thin pieces of rubber (green and red) and finer details.
To make the shoe, I used a simple purple slipper with more rubber glued and not to get too heavy I did finish with green ink. Underneath it all I used a simple black jumpsuit with springs at the height of the belly, that is not recommended for very hot places like here in Brazil for example, I spent a lot of heat in.
I hope you like it, it was really beautiful. At least worth the effort spent.The total cost was about U$200 (something like R$350 real Brazilian currency). The kids loved it.