well not much, but here goes:
Okay, so as I'm at university now obviously I can't spare that much time to work on my suit, plus the suit itself is in a garage about 20 miles away from where I currently live, so updates are going to be rare.
Here's what's going on; I've been thinking about my helmet and my horns on the helmet for a while. Because of the shape of the horns, it's extremely difficult to work on the structural integrity of them (fibreglass the inside for strength), so I remembered something a few of the 405th guys used to do. What they did in situations like this, or as a lazy/excellent alternative to fibreglass was to mix bodyfiller and resin together.
I'll be honest, I don't know the mixing parts, but I get it to a fair liquid consistency - not too runny so it won't stick to anything, and not too thick so it won't flow, but just right
. The idea is to pour the mix (they call it Rondo) into the thing
, be it a horn or the whole helmet, swirl it around so the Rondo covers all the walls of the shape, and leave it to dry. It solidifies pretty quickly because of the body filler mixture, which dries very quickly anyway, but the whole drying process should take about 24 hours.
Much to my delight, the result is exactly what I needed for the horns and a couple of other places on the suit that would be otherwise really difficult to get to with fibreglass, like the inside ridge of the shoulder pads.
The only things to be cautious about this process are
A) Having enough body filler for the rondo mix and
the the suit exterior for smoothing. I may need to buy another tin because of this, but well worth it.
B) Small holes in the papercraft. Because the mix is obviously liquid, it'd be horrible if it started leaking everywhere, so it's good to make sure the pieces are properly constructed and stuck together with no small holes, but also going around with masking tape to just seal parts off.
C) Weight difference. There is a difference in weight if you compare this method to just fibreglass. This method does increase the weight significantly, but as long as the dried rondo mix isn't something stupid like an inch thick, and your bones aren't made of crepe paper, I'm sure you'll be fine.