You asked me this same question in a similar thread I posted a while back and I have to ask you why it's so important for someone to play the game to make a SM costume. I don't play the game either and I'm also not Iron Man and I built one of those costumes. If we want to make the costume that's it and our relationship with the game shouldn't really make a difference to you at all.
good start :thumbsup Im going to be doing a foam build just assembling items as I can.. love to see more I have learned allot on this how deep it can really get. Still have some confusion into the chapters but figured out a ton on the Templars..
Very excited to see you doing Black Templars! Played years back and picked their chapter for my figures mainly because they looked sweet, so naturally I can't wait to see your finished product. I am curious though if anyone has ever done an emperor's champion build from this chapter Good luck!
I'm looking to build a full sized marine Shoulder pad and am struggling to find any sort of template at the moment or indead any consensus on what is the best template, I have a pending registration at obsuricus at the moment and am wondering if could pick people's brains a bit I guess, as for the build itself have you ever thought about looking to European L.A.R.P weapon design for building the weapons.
Basically a Fibreglass or Carbon Fibre rod as the centre for rigidity usua;lly around 14mm thick, then using LD40 foam to shape the weapon itself then painted and latexed. I have seen some amazing stuff done by a few people in that style. if you google Death Unto Darkness their forum has a load of pics of an artifakes khornate bloodaxe and a two handed Sister of Battle Chainsword.
I'm not really much help in terms of building them but I can dig out a couple of my guides if theres any interest? the bonus of the Larp style construction is that with pulled blows you get something that's fight safe which is always cool, just imagine a duel between a CSM and an SM with Bolter and Chainblade outside a con.