I started out by making a paper pattern with poster paper. You can find my work log here:
Then I cut out the pieces from craft foam, assembled them with hot glue, and primed the foam with two layers of Mod Podge (Matte Finish).
Here is how I added the details and painted the armor:
I created the hair donuts with curtain grommets and craft foam, then painted them gold. I cut fur and glued that on the inside rim. Then I braided the hair around the ears and will be adding alligator clips to the hair donuts to keep them in place.
Tutorial here: https://youtu.be/3RzAK3g0gEI
The process is similar to the chest armor. First I pattern out the leg armor and cut it out on craft foam. I heat-form it slightly to my leg by putting it over heat (in my case, my stove top). Then I hot glue the various pieces together and added elastic straps. Then I mod-podge, spray paint, add weathering, and then add more mod-podge.