I bought a black leotard and tights, and a pin that I painted to be his classic yellow smiley face. The mask was made from craft foam and attached with spirit gum. I also purchased a toy gun and holster. The elbow and knee pads, shoes and gun-belt were already owned.
The blue shoulder armor was made out of wire and paper mache, which was covered in bondo, sanded down and then spray-painted. The red-white sleeve was a modified t-shirt sleeve.