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zel
good luck! this sounds really interesting!
as for texture for the armor, I think it would be a lot better to do it by hand with paint (look up faux finish books at your local library) instead of actually printing it out.
I was thinking about trying to dip papercraft models into polyurathane, maybe you can try using that to seal it?
as for enlarging it, heres some tutorials: http://www.benchnotes.com/Pattern%20Making/Pattern_Making.html http://www.instructables.com/id/EO8X29151CEXCFD0DD/
I think the black jumpsuit with polyfill would be much easier than to making it out of paper.
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