(Papermache) Armor hardening technique. (In need of assistance, invovles Lacquer)

[The Prop Lord]

I hate to post this here but I couldnt figure out where else to post it.

Long story short, my mom has a friend, who has a friend, who's son has cancer. He is in the military and was shipped out like 10 min away from where I live.

In the past 2 months we've become great friends and it turns out he loves making armor and props but is kind of a newbie to it.

I am by far no expert, which is why I need some advice about hardening armor / making it more durable.

He made Goblin Armor from LotR, Hobbit, from papermache' and doesnt want to redo the suit from other materials such as EVA foam (Love that stuff.) He put a lot of work into it and wants to make it more durable.

He's getting shipped back home and he plans on going to a medieval fare of sorts. He basically has 2 weeks to get his armor hard.

I know the correct way is to use resin. Preferably Bondo products. He wants to try out Lacquer. I never used it before but he said that when they Lacquered his deck or what not, there was a bit left over in the pan or can, or whatever they were using to apply the product.

He says that it was extremely hard and durable but, having never used it, I am skeptical. He doesnt want to use Bondo because it stinks and doesnt have time to mess with all the steps.

So basically, would Lacquer work for making the papermache more durable / harder?

 

[Darth Lars]

No, Bondo is a putty for filling, not for strength. It is used because it is based on polyester resin used for fibreglass and therefore very compatible with it.

The common way to reinforce pepakura (paper) armour is to use fibreglass. Polyester resin is the most common resin for fibreglass, but you can also use epoxy resin which does not smell (as much) but is more expensive. Most stores that sell fibreglass supplies should have epoxy resin.
From another point of view, pepakura armour is not really "paper armour", but "fibreglass armour" where the purpose of the paper was mostly to create a template. Some makers removed the paper completely after glassing. I am far from an expert on fibreglass and pepakura, but there are many threads about "Pepakura" in the costuming forum with lots of more info.

Lacquer is traditionally used for reinforcing works of papiér maché, so your friend is not wrong about that. For instance, paper and lacquer has been in Japan used for centuries to make household items that are very durable, items such as bowls, drinking cups, and even small furniture.
I think that fibreglass would be preferable if the armour is very large, though.

 

[The Prop Lord]

Thanks a TON Darth Lars! Really appreciate the advice!

I pepped once. Use it for reference from time to time, but I prefer to free form EVA foam. Im going to post my templates for Dark Knight Rises Batman suit as soon as Im done. I have never had need to harden it though because EVA foam is durable by itself.

Again, thank you very much!