(Please see the "Article on THe Flash" thread for complete article)
"The Flash’s remarkable outfit on the show (a character in and of itself, referred to as “The Suit” by the TV show’s production personnel) was a special effect unto itself. Costing $25,000 apiece to make, the 8 different suits used in the series were comprised of a mixture of spandex, foam rubber muscles, and a flexible outer sealant, giving the suit an unusual texture and a very macho, sinister appearance. This was no simple bodysuit; it looked more like a suit of armor than just a pair of form-fitting tights. And that was exactly the look the producers wanted. Overall there were two suits made for Shipp, two suits for the show’s stuntmen, two for photo doubles, and two for close-ups."
From Starlog NOVEMBER #160, Helping The Flash See Red article by -Marc Shapiro
"(Bob) Short met with Flash executive producers Danny Bilson and Paul De Meo. They made it clear they wanted a costume with a sinister tone to it, that it shouldn't look like a guy in tights, and, most importantly, it should look like a makeup effect rather than a costume technique.
Encouraged by this blue print and the costume design work of comics artist Dave Stevens, Short went back to his shop, did a little experimenting and came up with a 10-pound wonder.
"We covered actor John (actor John Wesley Shipp) with a bit of spandex," explains Short. "Then, we sculpted foam rubber muscles and applied them over the suit on John's real muscles. We then applied a flexible sealer of electrostatic nylon and sprayed that over the foam rubber and spandex, creating a surface coating and, when filmed, creates the impression of an odd surfice texture that makes it hard to figure out what the suit is made of."
Short claims that he also modified the costume's belt and boots and did a subtle redesign on the cowl line to give the Flash more of a scowl.
"Our concept of the costume," elaborates the FX expert, "was to create an impression of the muscles being on the inside of the suit. We think we've accomplished that by sculpting slightly exaggerated replicas of John's muscles, applying them to his own muscles and giving the impression of actual movement during the action sequences. Some of the construction of this suit is the same kind of stuff that was done with the Batman (1989) outfit, but we feel we've given it a more coherent, one-piece look which is the look that the Flash has in the comics.""