does any one know any strenthening methods other than fiberglass and resin. ive seen aobfrosts hot hot glue method that sounds very promising but if there is any more ways i would like to find out
You can also use wood glue (the white one). It will take several layers and patience to have a good result. It's simplier but it will never be as strong as fiberglass + resin.
The urethane plastic method Mac mentioned is a great way to strengthen your pep pieces. Here’s a video tutorial from the great Jedistumpy on how it’s done.
As pooper mentioned smoothcasting pepakura is a viable option... Archille wrote a whole step by step tutorial with lots of pictures over at the 405th Source: http://405th.com/?p=574
All the tutorials they have are for Helmets. They need to get one up for body parts. I'd do it but I just finished plasticing my body pieces I needed to.