I've just answered the eleventy-billionth question regarding where I get all of my stuff and how much it costs. I'm going to put my reply here (even though apparently nobody reads these parts) in the hopes of answering these questions before anybody else asks me. I'm sorry if it's rude, but I'm just going to start deleting PMs that ask questions that are already answered here or in the stickies.
I've put links to all of my suppliers in the progress thread.
I've stated exactly what I've used in my progress thread.
No, I can't give you lessons on molding and casting. For more information, get a copy of
The Prop Builder's Molding and Casting Handbook and figure it out like I did. It's not all that difficult and the book costs less than $15.
If you don't want to read a book, all of this information is available in my thread and in the stickies. If that's too much effort, find another hobby.
My molds so far are silicone jackets with fiberglass mothermolds. For the helmet and torso armor I've spent about $800 on silicone and $90 on fiberglass.
Casts are made using urethane resin filled with microballoons and milled glassfibers. Bigger pieces are reinforced with fiberglass matt as well. So far I've spent about $1,100 on resin and fillers to make half a dozen helmets and four sets of torso armor.
All of my cost estimates are probably on the low side because I have a fairly well stocked shop with a lot of materials on hand that I would've had to go and buy otherwise.
Suppliers I've used are Smooth On, JGreer, and Tap Plastics. I'm not going to Google it for you.
Please stop sending me these questions and read.