So far, I've spent far more than I should have and gotten less-than-great results. I've finally got a method working now, so here's my estimated price list for a brand-new scratch-build:
$5 2 reams 110-lb card stock
$100 2 gallons fiberglass resin (don't buy them both at once)
$40 2 gallons bondo body-filler
$12 2 packs fiberglass cloth
$20 ~20 side-release buckles
$10 Polypropylene webbing
$30 reflective visor
$20 LEDs, wiring, battery pack, switch
$20 sandpaper
____
$257
$50 Good respirator with VOC filter
$50 mouse sander
$50 moto-tool with bits
$25 Saws, files, exacto blades, etc
not including anything for the undersuit. This assumes building armor from HD pep files with the
mud-glassing method.