No, no, I doubt I was THAT Thanatos, because no con would permit me entry, because the EPIC COFFINS stuck out like 2 feet and were all set at different heights, they also moved with my body (not my arms, muscle flexes controlled them.) They said I would be too great a distraction....
Also, cardboard isn't as ghetto as you'd think, have you seen some of the cardboard visual tutorials on cosplay.com? I saw an Automail Arm that looked scary real. But, fitted plastic could work, but that's hard to work with. Could go with insulation foam, it's what most people use for accessories of that nature. If it weren't half past midnight I could probably help more.
@ Asylum: I second that motion and will draw up plans immediately following the completion of my Arakune cosplay! (If I work on more than one concept at a time I end up with weird stuff...like the time I did a sketch of Nu for my friend's cosplay and ended up with Zeta, some weird male version...)