Can't help you with sewing, you're on your own there, but here's a thread about new Zod figure that was recently released that you may find handy when designing your costume for Comic-Con:
Just make sure you don't make ANY of his costume shiny red like that figure. The shiny red parts should actually be shiny black. I don't know why the hell they did that to his costume for that figure. Other than the red shit, the outfit is pretty accurate.