Nerf Armor

Many years ago I made up a character for a tabletop pens&paper books&dice Hero game. He did not get played much, but the image has stayed with me. (I probably shouldn't have done a large color pencil drawing of the character in hindsight)

The basic concept was a guy who found a way to make Nerf into armor, and a non letal bashing weapons. He was dressed from head to toe in an old fashioned articulated suit of armor, made of Nerf, and had a big Nerf Mace. He was known, of course, as "The Nerf Knight" The entire costume, mace included, were that strange shade of electric orange that screams Nerf.

I was wondering if anyone had ideas how to best create a similar character in CoH. I am thinking Tank. In the "Hero game" he had 75% damage reduction to all non psi damage, some moderate resist numbers as well. The game systems do not match up exactly in how damage is applied. I can see it as a mace tanker pretty easy, but cannot decide on the armor type. Any ideas? Or should I wait and see if Bio fits better?

Hmmm. I thought about it for a couple hours. Ran the Mids on all tank armors (Ice is interesting, wrong for this though) and decided I do not want to make an uber build. I just want to have fun with an orange maniac and a mace. That led me to think just go easy SO build on Willpower/Mace. And it clicked. My 1st DFB only character. Wish me luck folks. An Orange Nerf Armor Willpower/Mace Tank sets off into the city., er, the sewer! to do justice, er, cleanup, er, whatever.

Some peoples idea of Nerf is different then others but, imo, the best armor would be something like Mace/shield just because it gives you more of a "knight" feel. As for asthetics, basically whatever you can make that looks both soft, pliable and colored in bright yellows and oranges, not unlike a Crashtest dummy. I would say use parts like the Olympian shoulder pads, bulky armor top and legs that give the impression of nerf pads. Maybe something like this.