A site selling sheet polystyrene. Same plastic model kits are made from. I've worked with it. I'd recommend .040-.080 for armor projects. Not bad prices for large sheets but if anyone is gonna try this feel free to look some more. I'm going to try this with my MK VI but I have a long way to go before I'm ready for the actual build stage. People may even have a plastics supplier closer to them so wouldn't have to order online.
http://www.usplastic.com/catalog/item.aspx?itemid=22883&catid=715
Another building idea i've never tried yet but seen examples of how well it could work is to take clays like Aves epoxy sculpt and roll it into thin sheets and apply over some type of mold or a pep model. It cures fairly hard into a plastic like material. I'm gonna experiment on the helmet with this. I just hate using bondo cause I have an apartment and the stuff stinks way too much. The Aves Epoxy sculpt may not be cheap for some but it's great stuff.
http://www.avesstudio.com/index.php...&category_id=7&option=com_virtuemart&Itemid=1
http://www.usplastic.com/catalog/item.aspx?itemid=22883&catid=715
Another building idea i've never tried yet but seen examples of how well it could work is to take clays like Aves epoxy sculpt and roll it into thin sheets and apply over some type of mold or a pep model. It cures fairly hard into a plastic like material. I'm gonna experiment on the helmet with this. I just hate using bondo cause I have an apartment and the stuff stinks way too much. The Aves Epoxy sculpt may not be cheap for some but it's great stuff.
http://www.avesstudio.com/index.php...&category_id=7&option=com_virtuemart&Itemid=1