So I had most of my suit built from foam. The tape failed on the chest piece so I had to emergency rondo parts of it to keep it from disintegrating. It worked, but not very well. When I coated it in rondo it looked decent, but when I went to sand it smooth it cracked off a bunch and looks like ass. I built a card helm and when I went to bondo the outside it set up weird and super lumpy, almost jagged. It's saveable, but not without a LOT of sanding. I've scrapped the first two sets of shins, both cardstock. One too big, the other got all warped when I glassed it. I have the template to make them from foam, but after the chest debacle, I'm hesitant to try.
Basically after 4 months, I have boots and thighs. The thighs aren't glassed, just taped up foam tubes.
I won't be able to finish by D*Con, and I know myself well enough to now that if I don't get it done by then, the pieces will just sit in a corner until I don't notice them anymore, like my Spartan Laser. So it's all getting tossed.
It was fun while it lasted.
WH40K Pepakura File Library 
