Download the patterns HEREThe sword is separate, pattern made by somebody else. You can find that
HERE.
THIS IS ALL
MADE FROM RIPPED CRISIS CORE 3D MODEL FILES!!! In other words... That thing you see on the screen? I'm wearing it. The image itself!

The pattern by itself takes about 5 hours to print, cut, and assemble. After that, cutting out the pattern, tracing it onto cardboard, cutting
that out, and assembling that all takes about 25 hours.

I suggest you get lots and lots of friends together to help you make this process slightly less painfully time consuming.
I for one would LOVE to see a whole platoon of SOLDIER cosplayers at a con one day.

Kinna makes more sense than 1,000,000,000 Zack clones, right?
I wish that helmet made sense. Can't see a darned thing, and it smells like pizza inside.

Enjoy!!