Robot build material reccomendations?

[takaaaa]

So I'm going to start a new build and need some material suggestions.
So essentially it's a full body robot costume. It's mostly composed of flat, sharp edges. Not so much rounded curves.
I have a pep file and was just going to build the pep way (pep, resin, fiberglass, bondo) but since it's mostly flat surfaces, it think it would make more sense to build it from a flat material, instead of bondoing it flat.

My problem is that idk what to use. There's a member here with a excellent Robot cosplay tutorial and suggests using corrugated plastic


This seems like a very good idea but the ones I can buy locally, show lines on the outside and I would have to cover them somehow.

Then I thought about using a foam presentation board, like this:




The problem with this is that there is a layer of paper. So if I were to glue it, the paper layer would probably start to peel off..

I'm not a fan or card board too since if you bend it, it will crease.

It's also quite large with a lot of surface area, so thin material wont work and might bend.

What kind of material would you suggest. I also live in Hawaii so we dont get certain uncommon materials.
Maybe there's a material that slipped my mind.

 

[Drack]

If the robot suits you are talking about are CliveLee's gundam suits then he does state in his tutorial that he covers the corrigated plastic in thin PVC.I think its a great way to do it because as you said there is a good chance of creasing with card.

 

[takaaaa]

If the robot suits you are talking about are CliveLee's gundam suits then he does state in his tutorial that he covers the corrigated plastic in thin PVC.I think its a great way to do it because as you said there is a good chance of creasing with card.

Yeah I would probably cover it in vinyl. Which seems to be the best option right now. Still searching if there is any other possible material I might be over looking.

 

[Drack]

This is what I will be using to coat mine.
PVC 545MM X 10MTR X 0.50 CLEAR ROLL

 

[takaaaa]

This is what I will be using to coat mine.
PVC 545MM X 10MTR X 0.50 CLEAR ROLL

I never worked with thing PVC sheets. How do you use it? Do you actually wrap it like vinyl fabric? or cut each panel and glue it on?

 

[Drack]

I am not entirely sure yet because I too havent used it but I was going to treat it like pep....kinda. The good thing about it is its rigid which means its sandable so you can clean up your edges.