Can't wait to see this! Good luck!

Wow, interesting construction technique. Looks high-tech and computerised..how did you make it?

Fibreglass and body filler would be stronger, but also way heavier, ..and you'd probably smell the fumes inside the helmet for a good year before it wears off. I've worked with fibre glass, it isn't easy to work with and is unpleasant when the fibres get stuck in your skin like glass splinters..

It's made using a program called Pepakura. It takes a 3D model and divides it into origami style pieces you then print onto cardstock, cut out, fold and glue together.

If you wouldn't recommend fiberglass, what would you suggest as a good alternative?

WOW! This looks absolutely great. The construction method seems really interesting! Well done!

Sent ya a pm cos it was a loooong answer. ;)

Good luck with the project, it's looking kewl.

gotta agree on the fibreglass front. it's horrible (to the point i swore "never again") stuff to work with, and all i made was a mothermould...

this looked epic during the expo well done and hope the hard work paid off..

Thanks LimeGreen. Had an awesome time at Expo!

To all who said that fiberglass was a bad idea... I have to disagree, I didn't have any problems with it at all and it made my armour pretty strong too. I didn't smell any fumes while wearing it, it didn't irritate my skin in any way and the armour didn't feel heavy. Maybe I just got lucky.

HOW DID I NOT SEE THIS! *cries*

That is awesome