Time to test init's theory: I'll be attending an event, not a Con, in Pune next month, real good thing, plenty of people and all that. I'll be wearing my Master Chief suit complete w/ gun, we'll see if the wimmenz flock to me. Updatesz: The chestplate: yeeha!
Not really but the way I'm making it, it should comfortably fit anyone around the 5'10-6'1 range, waist isn't an issue you can be 32" or 48", it'll fit. And I measured a couple of heads before making the helmet so it'll probably fit anyone.
Deadline's on the 10th of next month for the underarmor suit, the individual pieces of armor and the gun too.