Want it to look amazing but be expensive and very time consuming or do you want it to be less detailed, easier to make, a couple hundred dollars less expensive and a lot lighter?
[spoiler]Pick one and I'll elaborate.[/spoiler]
It's in excess of $1,000 and requires knowledge of how to safely handle fiberglass, resin and power cutting tools.
[spoiler]I'll link some articles of how to do it and I can fish around for files of your armor if you give me specifics.[/spoiler]
That's necessary to find the files.
The method that you'd want to use first involves getting something called Pepakura [b]Designer[/b]. The full version (where you can save your edits) costs like $50 but you can use a trial version just fine.
What it does is gives you diagrams that you can use to make the armor pieces out of cardstock paper. Sounds flimsy but bear with me. You cut and glue, not tape, these pieces together and when you're done with a piece you slather it in resin on the outside and fiberglass on the inside.
You'll end up with a very detailed, very durable, paintable armor piece.
I can explain more if you need me to and I'll link some articles.
Oh I remember seeing a video where a guy used that. He made a very detailed helmet.
Also do I lay the paper sort of over lapping or literally edge to edge?
They'll have little tabs where you glue it. You'll see once you print one sheet out.
Make sure to mess around with the scale (I can tell you where the setting is if you can't find it) so that it fits properly. Ideally you want a little bit of room on all the pieces except for the helmet so you can add some padding. The helmet should be a considerable amount bigger so you can have a lot of padding.
Just make sure you try the size once your paper part is done before you fiberglass it.
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