to construct the helmet to spare Weller the polyurethane smell. Seven suits were made, including a fireproof version for the gas station explosion, and damaged suits to reflect the aftermath of assaults on RoboCop. The suits weighed 25 to 80 lb; reports vary.

Once completed, Weller tried on the costume. It took around 1.5 hours to put the outfit on. Weller was immediately frustrated because the costume was too cumbersome for him to move as he had practiced. Bottin spent 10 hours adjusting the outfit to help alleviate Weller's concerns.