Shane Ruff of Ruff Studio went big for Halloween a few years ago. He and a pal made two elaborate gargoyles costumes that involved moving wings and stilts. The heads are a base of hard foam attached together with what appears to be electrical tape and softer foam was added to fill out the shape. A third layer of liner foam finished out the look of the head, and he used 3M spray glue to attach it. The wings were attached to a backpack harness and crafted from two layers of fabric, PVC pipes, poly batting, pipe insulation tubes, and hidden wires.
See an album of work in progress photos at Facebook.