Hey there, welcome to the amazing world of prop and costumes making; I have been working on my armor or a couple of months now and here is what so far I have learned.
1. What is the purpose of the brace (like the chest brace thing?) is it something I really should build?
I thin the brace is used to keep the torso (chest/back) in place and be more stable.
2. I used 110 lbs cardstock paper and superglue; if I would like to strengthen/harden it and skip the bondo process, (yes, I know it won't be smooth but I just wanna skip this step) what would be the best thing to use to strengthen/harden it? I've heard the names Smoothcast 300 Series and EpoxAmite, and of course the fiberglass, and I'd be fine with using fiberglass mats/tissue but I was sorta looking for maybe an alternative resin substance thing? I'll use fiberglass if I have to though, I just want the suit to be hard, strong, and sturdy, and not real flexible when I'm done with it
This one; a pro needs to answer, have you think about using rondo (Resin/bondo) you can use is like paint since is very liquid, use a good brush that won't leave a lot of marks and a light sand, presto that may work.
3. Even though I used 110 cardstock, some of my peices (mostly like the chest and back peices) are kinda floppy at times; they keep their shape and were pepped very well (sorry I'm bragging but just wanted to make sure ya'll didn't think I did a crappy job) but don't always stay in the right position (like when I set the chest down on a table or something it gets more spread out) how would I make it stay in one position while strengthening/hardening the peice? I don't wanna have a weird looking chest or back peice...Hopefully I made this question clear enough haha
You can use some craft sticks to give the parts some support; take a look at my build and you will see what I mean
http://www.therpf.com/f24/my-hd-war-machine-suit-pic-heavy-151527/index4.html
4. I pepped Sharkhead's helmet (the awesome one with the teeth and stuff) and I'd like for the faceplate to be a seperate peice (that's what it's designed to do after all) but how should I strengthen/harden the helmet? my faceplate is sorta warp-y and doesn't fit onto the rest of the helmet by itself, but when I tape it to the helmet it's perfect-looking; I worry if I harden/strengthen the faceplate by itself and the rest of the helmet by itself, it won't look right or fit together right anymore, so I wondered if I should strengthen/harden the helmet with the faceplate taped on? If I did that, I'd probably have to cut the faceplate out after it's hardened, right? But what tool would I use to cut it?
A dremel with a hand piece extension that way you can handle it better; here is a link to that
Flex-Shaft Attachment-225-01 at The Home Depot
Last two questions I will leave it to the pro's here...Good luck and post tons of pictures when you start.
5. I've seen on this thread something about resining or hardening or whatever one part of the helmet at a time? Does this refer to the actual parts it was made to seperate in (faceplate, jaw, etc.) or just refer to not doing the whole thing at once?
6. And finally, are there any other armor peices that it would be preferable to harden while attached to each other (like should the chest be connected to the back when I harden it, or should the lower circular part of the forearm be connected to the upper bulkier part of the forearm? Are there any other peices that should be attached to each other while hardening?
Thank you so much in advance![/QUOTE]