In my opinion, deleting old threads is a bad idea. I started researching old threads when deciding to do the armor from Halo CE. Posts 3-4 years old were invaluable for research. Besides a lot of the old posts still have relevant information and file links that did not make it in the database...
Thrift stores or local hospitals are a good place to find old crutches or canes. Cutting out the adjustable tube part and epoxying into the stock should work.
You might want to try using Mod Podge as a sealer instead of acrylic spray. Mod Podge brushes on instead of spraying, but can be washed off the brush with soap and water. It is water based so make the first few coats very light to avoid warping the cardstock. If sticking with acrylic sealer then...
What are you using for glue? Being water based I wouldn't think it would dissolve any glue types. That might be from the Krylon acrylic spray.
Are you doing the ratio based on weight or volume?
Also what part is powder and which is liquid?
I have been experimenting with Aqua-Resin in my Mark...
I would suggest watching the videos by Cereal Kill3r Studios on YouTube and his build in the elite section here on the 405th. In them he talks about using a rasp to grind down the sharp pep edges for areas needing to be smoothed. Another thing he suggests is putting super glue on the paper edges...
After the build is over, I would be really interested to learn your techniques for Aqua-Resin. For the bondo issue you could try aqua resin also. My attempts are at the end of the Mark V build linked below.
Where did you see duplicating content, especially for a all in one sticky type post, is against the rules? I just looked through all the forum rules I could find and nothing about duplicating content was mentioned.