So...I've made Master Chief pep helmets, did the whole fiberglass and bondo thing...which is a TOTAL pita...
After reading the foam build threads, and this one here, http://www.therpf.com/f24/how-plasti...pieces-146539/
I got to thinking.
Is there ANY good reason why we can't make the pepakura piece of armor out of cardstock, reinforce the OUTSIDE with a couple coats of fiberglass resin...and then just do a slush cast of the armor piece with the Smooth On??
Then all you'd have to do is peel off the resin cardstock, and you'd have a solid resin piece ready for a little bondo, sanding then paint!
I'd try this myself, but I don't have any Smooth On in hand, and was thinking if anyone had some, they wouldn't mind doing a small test.