How about using metal flashing for armor? It's fairly flexible, durable and cuts pretty well with a knife: you score & tear along the seam. Ripping metal is a satisfying sensation (me stronk!). And it comes it 2 flavors: aluminum & steel.
I've done some primitive shapes with it for my mech using rivets (toying with some MJOLNIR armor for it just for lulz of having a 1:1 scale spartan), but you could probably use other adhesives in a more Pepakura style with tabs & whatnot.
I'm thinking roof patch rubber with a few rivets to hold it together might be good. I helped my father patch his roof last spring and my work gloves are still just as covered as day 1. Only downside is the metal edges are a bit of a hazard, but probably can be mediated with some cloth brushed with aforementioned roof rubber. (And wear some thick leather gloves when working with it!)
Think of the bragging rights: "Oh, yes. My armor is aluminum." If you bang it around and the paint comes off, it will reveal shiny metal underneath instead of foam/bondo etc. Makes weathering it a bit easier...
Probably some fine detail would be a challenge but... whatcha think? I'd put my money where my mouth is but its -5 F outside and my garage ain't much warmer D:
I've done some primitive shapes with it for my mech using rivets (toying with some MJOLNIR armor for it just for lulz of having a 1:1 scale spartan), but you could probably use other adhesives in a more Pepakura style with tabs & whatnot.
I'm thinking roof patch rubber with a few rivets to hold it together might be good. I helped my father patch his roof last spring and my work gloves are still just as covered as day 1. Only downside is the metal edges are a bit of a hazard, but probably can be mediated with some cloth brushed with aforementioned roof rubber. (And wear some thick leather gloves when working with it!)
Think of the bragging rights: "Oh, yes. My armor is aluminum." If you bang it around and the paint comes off, it will reveal shiny metal underneath instead of foam/bondo etc. Makes weathering it a bit easier...
Probably some fine detail would be a challenge but... whatcha think? I'd put my money where my mouth is but its -5 F outside and my garage ain't much warmer D: