I´ll give you my opinion on how to... mull this problem over.
Listen up, if you don´t like my idea please don´t shoot me, just trying to help.
I have been lucky enough to buy a armor though I´ve tried a lot (before this site was even on) and everything failed. Now using this site and before I found my NAS armour in my mail box I tried a diffirent approach. Listen up ya´all.
I took the pepakura armor including the pepakura program, took it with me to a ,what you call m in america?, Print shops (the proffesional ones with the big machines) and orederd them (for the right money) to print me that armour scale 1:1 and a sort of cardboard/paper combo. Making it flexible but sturdy enough. Works very well and is very very cheap! Then after having donde that I would´ve fiberglassed it. painted is (maybe even detaill it a bit more with greenstuff *warhammer* and things).
I never came to finish it, gave the kit away to a friend (because at that moment I got my armor in) but the helmet (which is the one I started on) came out very very nicely. Thats the option I would recomend you!
Then after fiber glassing it u can paint it ,etc.
Enjoy!