Gary, that looks awesome!
For the gray material, can't you just brush urethane into the mold and back it with a fabric material like the red material, either nylon, milliskin, or ...?
Also, I went to Lowes and they actually had two brands of lenses (or "troffers" as they were labeled): the Plastikote sample you started with that had the elongated diamond shapes and a Metallux brand. The Metallux one had cells that were almost perfectly square like the new sample you have. Check it out if you have a chance and see if it's the same as the new sample you got from Plastikote. The cells in the Metallux brand troffer may have more depth than the new sample you recieved, or maybe not. Could be worth checking...
George Men's All Guy's Jacket: Men : Walmart.com
Looks like they changed the name from Squall jacket to All Guy's Jacket
I dare somebody to say something about Gary's samples so far.
Other than they are F'n sweet???
Black or grey? I'm assuming that grey would be the best to go with.
Got any kids Gary? Wanna adopt me? Lol
Step kids.
I'm curious to see if my ideas on how to build a BETTER jacket have merit. I'm not looking to copy the original prop as made in 1989. I want to see if it's possible to use MODERN materials and techniques to improve on those original designs (just like I try to do with my replica time machine).
If people here can use those techniques for their own efforts and final projects then I've done exactly what I wanted to do.... help.