nickytea
Master Member
I don't know if you've seen my thread for the Proton Pack I put together for Halloween, but a large percentage of the pieces were constructed with foamcore to help offset both weight and cost. Might be a good option for you.
http://www.therpf.com/f9/yes-im-sorry-another-proton-pack-thread-99187/
http://www.therpf.com/f9/yes-im-sorry-another-proton-pack-thread-99187/