Ok, I've been led to this site via Honus' instructable on how to make a fett helmet out of cardboard. I searched the site and read up on a lot of scratchbuild techniques before starting my build.
Thanks to Honus and others for the inspiration and to Alan (WOF) for the templates.
For the cardboard I'm using mat backer board - It's some type of cardboard/paperboard used in mounting pictures in frames. It curves well without creasing and a full sheet was $0.99 from the local craft supply. That's for enough material to complete this project !
I had a partially used Bondo fiberglass repair kit which was used to fix a split in my bumper. It would probably have gone to waste in my garage but now it's going to help me make a durable, affordable Fett Bucket!
Here's my progress so far:
Back insert remover to ease the interior fiberglassing, you can see the sheen from the Mod P:
Here you can see the interior covered with the woven fiberglass and resin:
The excess fiberglass mat has been trimmed off on the right using a dremel sanding wheel:
Fully fiberglassed dome the exterior cardboard is now only for detail, not strengh: