So, this is the costume I went with for Comic-Con this year:
T-shirt has the exact number of armor bubbles front and rear for a GRF-1N. Head's mostly craft foam with some cardboard, made by my wife. Unlike my previous UrbanMech and Shadow Hawk ones, i could actually turn my head in this one, look down by my feet, and generally walk around without issues. We skipped the canopy panels for air ventilation.
Improvementsfor next year? Thinking of incorporating cooling fans.