oh i saw someone cosplay his on cosplay.com it was awesome!
if you pull this off you shall be the ultimate FFVII:DC cosplayer lol
I have a plan to make 'spring release' wings for Chaos but i never got around to planing anything else about him :P ..... Kudos on the choice costume :P he is amazing :P make the materia light up and i'll buy you a hug XD
O.o Serious good luck for this - I bet it's going to look completely amazing when it's all done though.