Hey, i saw your post before that asked if there was a way to make pep without cardstock.
what i used to do was use 4 sheets of regular paper glued and sandwhiched together. It actually worked better than cardstock but adds a whole other step to the process.
Hey man, thanks for checking out my thread. As far as methods for making armor, pepping is by far the best way to get great looking pieces that are to scale and relatively easy to put together. But if that's not you're thing, I've also used cardboard to make the suit I'm wearing in my avatar pic. It can be a great alternative if you're good at making freehand models, and don't have the time to spend on a detailed armor piece. For that I would check out the pep and cardboard armor section of the forum under creation discussion. There are also people who use clay to sculpt the pieces, then make molds and cast the armor with a two part plastic mold. But thats on the expensive end. Anyway, hope this helps. Good luck!