Many parts to this costume! So, hmm, let's see...
Body Suit was hand-drafted with multiple panels for the different colors. (I have a tutorial here
where I explain my process)
Cape was also drafted from scratch, with multiple mock-ups to get it right. The yellow "seamless" trim was added with a technique I describe here.
The shoulder armor was probably the hardest aspect of the costume, because I have limited experience with armor/props and not a lot of equipment to do something really fancy. What I ended up doing was use thin cardboard to create the basic shape (after doing several mock-ups with stock paper). Seams were held together with glue/tape, and there's some thick wire to help hold it's shape. Then I paper-mached on top and painted, added details, etc. Not the most comfortable thing, and the closure started falling apart at the con.
The wrist and ankle cuffs were made using various things from the plumbing aisle at Home Depot. The plastic tube for the ankles had to be sawed down the middle in an odd, difficult shape to match the references. There's also some craft foam involved, including the chest-plate thing. All the "metal" pieces were sprayed with metallic silver paint.
Other pieces include: the belt, the whip (altered an existing one with a paper towel roll, etc), and the glasses. The glasses were made from scratch, with a cardboard base. The purple plastic was REALLY HARD to find, and then painstakingly hand-sawed into shape.
The wig is described below.