Antony Le spent a month and $4,000 building this very realistic costume for War Machine, a character from the Iron Man franchise. The faceplate is powered, and the gatling gun actually spins:
Le, a fitness consultant, studied some concept sketches of the suit posted on the Internet. He used thin, high-impact urethane for the armor, cutting it into plates and joining them with some 1,500 rivets and washers. He sculpted a clay helmet mold and then used a liquid resin mix to create the final product. But that was just cosmetic work. He also added a small servo motor that opens the faceplate, as in the movie, and built a gun out of pipes and a motor. LEDs in the eyes and chest-plate further add to the illusion.
Link via Geekosystem