Terrorsaur was my second mecha cosplay, and he came out much better than my first, though he had his issues, too. I wore him for OTFCC 2004. I may have also wore him for TFcon 2004? And maybe one Halloween.
My memories are a bit unclear.
He is based off the show model of Terrorsaur, but he's fairly heavily simplified. None of the fabrics were spandex, and the black and the silver really, really liked to fray. I had to use watered down glue to keep them from fraying. The red scale fabric was really hard to sew. The ribbons hanging down along the sides were meant to be some wires that his design has. His helmet was made out of a cheap plastic construction helmet, Model Magic, craft foam, paint, and too much glitter, in retrospect. The shoulder and knee points were made with craft foam. The shoes are just red shoes that I happened to have and were probably not the best choice. The optics were just red overhead film taped to my glasses. The wings were just some demon wings I found at a Halloween store. He does have some problems with wrinkling. The gloves were made by taking red gloves and colouring the fingers black with a Sharpie and then adding some black puff paint for the the joint markers. This time, though, I used Ben Nye Lumiere Luxe Powder as my face paint, which did work well.