I'm going to go through the steps I took to create my warrior. I'm not going go into to much of detail in every step, but more to show the workflow and how I think while working and the overall process making it.
First thing I had to build was a generic body mesh of a man. I wanted to be sure that the armor parts fell into the right places, and wasn't going look strange or out of proportion. So, by having the whole body underneath and working out of that as a template, it made it easier to build the parts correctly. I'm always using and reusing my meshes, so I can speed up my progress in more complex scenes. That's why I used an earlier built mesh that I had already completed. I modified it so it could be used as the warrior's base mesh. For inspiration when making the armour, I was looking in all kind of places, Warhammer art, LOTR movies and pictures, spawn figures, comic books and anything that could give me some nice ideas.
When all of the armor parts were built and done and I was satisfied with the design, it was time to start preparing the model for Zbrush. First thing to do was to apply Uvmap coordinates on everything before exporting it. I didn't want to Uvmap in Zbrush because I felt that I had more control doing it in an other 3d application than Zbrush itself.