Hi all - I've just been going over vacforming threads and my head is spinning with ideas for future projects! However, I need a bit of advice on a project I'm working on at the moment for a client. i've been commissioned to make a Jaime Lannister costume from Game of Thrones. Fabric and scale mail components are fine, but the breast plate is what has me worried. Images of the breastplate: http://27.media.tumblr.com/tumblr_lc3fz7T2Sb1qbmmu7o1_500.jpg http://www.spoilertv.co.uk/images/c...r-game-of-thrones-17904592-500-281-1-_595.jpg To keep the weight and cost down (and to hopefully give me the option of selling copies later) I'd like to vacform the front and back pieces in ABS. I've done a little bit of spectacularly horrible (and highly educational) vacforming in my tiny kitchen before (using DrCrash's instructable as a guide - BRILLIANT) and as this is a larger scale piece, I want to build a buck that is going to stand up to a bit of wear and tear...but not break the bank. Right now, to give me a torso-shaped shell to work with, I have paper mache'd a male mannequin. Yep. Would treating this similarly to a pep model work to strengthen it for forming? Ie, coating it in resin and reinforcing it from the back side with fibreglass or "rondo"? I was planning on starting out with plaster, to keep costs as low as humanly possible while playing with a new technique, but I'm very concerned about it just not being tough enough to stand the abuse it will no doubt get. I'd also like to get it right, or as close to right as possible, the first time! Thanks in advance!