I Need Help With Darth Vader Armor

Yes, you can sand it back to the foam sheet. This is something you should do in a well ventilated area and a respirator, that epoxy is not something you want in your lungs.

That spot will be hidden by the cape, so even if it's less than perfect after the repair, it won't be seen.

ETA: in fact, I'd go ahead and sand the entire piece, then apply a second coat of epoxy to get it evenly coated over the entire piece.
 
So i got it all sanded and then cleaned it with alcohol. Then i felt this overwhelming need to lightly paint it so i could see all the spots i missed, but after spraying it i didnt miss but a couple so its almost ready for a new coat of epoxy. Now just to wait till the paint 8s completely cured.
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Quick update. I applied 1 coat of epoxy and after it dried i put on all the putty to fix all the bad spots. Now when it dries, i can get to sanding.
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Yet another update.
All sanding done in the first pic then i sprayed a coat of black primer just to see if i missed anything. Next i will coat with 2 coats of epoxy and if everything looks good i will get ready for final paint and clear coat.
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Well firat coat of epoxy is on, now i wait till 6pm tonight to apply coat 2 and that should do it. Im pretty sure after the 2nd coat all cracks and blemishes should not longer be visible. We will see.
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Yeah cause evertime i tried to add them, no matter what i used or how i did it, they didnt look right. So i said to hell with it.

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Well I got it painted black, (but forgot to take pictures) taped up and then sprayed grey. I know the color doesn't exactly match but i really liked this color. So i hope it looks good when i untape it.
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Ok, paint is dry, and i removed the tape. I think for the first piece of armor i have ever built it looks good. The grey is a little lighter that i expected but i really like the color. Now just to strighten up the paint lines and coat with one more coat of epoxy.
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Well i still need to epoxy coat it but i couldn't resist. Still have a little bit of clean up and need to bend it into shape a bit more, but i love the way it looks.
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Yes that is the black series helmet and i haven't gotten to work on the shoulders yet because life has beed way busy.

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