Update is in order:
Fran: Jaina Solo (myself) [link]
Balthier: Einlanzer [link]
Photographer: Alain Camporiva/Idolotry Studios [link]
The Fran armor was make from craft foam (foamies), glued together with Krazy Glue and painted with cheap acrylic paint you can find almost anywhere (I think I got mine at Michael's). I used WonderFlex minimally, mostly just to back the snaps that held the armor onto the costume (because sewing through craft foam would tear the foam) and under the helmet to give it structure and allow me to curve the side pieces close to my face. The bodysuit was patterned by me and made with a generic black pleather; I learned a basic maille weave and created two chainmaille panels for the sides using black aluminum rings; the ears are made of Wonderflex covered in faux fur and bolted onto a headband; I used two wigs, one clipped onto my head and one for the ponytail, with just a foam cone inside the head wig to give the elongated ponytail look (it's held in there with only a single hair tie so I can take it down and redo it if the wig gets messy or tangled).
I think that just about covers it all!