Ok, I'm super confused about what you're doing, now. This is what I think I'm hearing...
You made Pepakura models, which you will make a mold from, then you will cast the piece in plastic, then add fiberglass, then add Kevlar?
I think that regardless of any of the stuff talked about here so far, the simplest, yet best result ("impact resistant" and "good quality" as you put it) would be to simply cast it in a high performance impact resistant plastic, like Task 12. A good pair of impact resistant glasses can stop low caliber bullets and shotgun pellets. Quality cast armor would be simple, you could make and test it in a variety of different materials before your final decision, and the result would be superb and highly durable.
It doesn't seem like there is a lot of sound engineering behind the current plan, although it does visit almost every possible combination of construction materials and fabrication methods (and also all the risks involved with each), all in one shot.
You made Pepakura models, which you will make a mold from, then you will cast the piece in plastic, then add fiberglass, then add Kevlar?
I think that regardless of any of the stuff talked about here so far, the simplest, yet best result ("impact resistant" and "good quality" as you put it) would be to simply cast it in a high performance impact resistant plastic, like Task 12. A good pair of impact resistant glasses can stop low caliber bullets and shotgun pellets. Quality cast armor would be simple, you could make and test it in a variety of different materials before your final decision, and the result would be superb and highly durable.
It doesn't seem like there is a lot of sound engineering behind the current plan, although it does visit almost every possible combination of construction materials and fabrication methods (and also all the risks involved with each), all in one shot.