I would also like to add that Melanie wins the internets even without the costume. On the cosplay.com boards, she goes into great detail about her materials and techniques when people ask for help. I love people who kick ass at what they do and are cool enough to share their knowledge with the rest of the class.
I made some progress on armor tonight, including work on Randy's poor neglected Xiahou Dun. It was one of those nights where you spend a lot of time drawing things and cutting them out and you don't have much to show for it except blurry eyes and a really boring-looking piece drying in the bathroom. Judging from the great job it did sticking vinyl tubing to foam, I think E-6000 will be plenty adequate for gluing foam seams together.
Funny how Otakon is 4 1/2 months away and I really don't give a crap about bringing a costume. I think I burned myself out on freaking over costumes last year. I'm perfectly content to bounce back and forth between my projects, and at the very least, I think Zhang He will finally be completed to my liking. (There's just that pesky matter of getting hair under the wig. I wonder if I can learn to make multiple parallel French braids on my own head before then...or if I ought to just bribe a stylist before we leave...)