I have been on this site for the past few weeks now working on this and first would like to say thanks for everyones help that has posted tutorial threads. They have defiantly helped a lot in this process.
Anyway I thought I would show what you helped me to do so far. I am working on a video project and needed Mandalorian armor, so here is what I have so far on the helmet. It's fitted with the visor and primed ready for paint.
That's my dad wearing the helmet. I have had some problems with it and may need to start over. It doesn't fit well for one, and when I put the epoxy on it caused it to widen out making it smash agents your nose... But if it looks good on camera we may have to deal with it.
The next thing I have been working on is the armor itself. I used floor mats found at home depo, or lows or pep boys. The pack of 6 sheets of 18 inch by 18 inch puzzle sheets was $12. I used paper as a templet and then cut it out of the foam. I also used a dremal to round off the edges and bevel it a little. The foam molds with a heat gun and then when it cools it keeps it's shape. I have seen a guy do Mass Effect armor with the same stuff.
This is after it was all molded. Next I used elastic strips to connect everything. I hot glued the elastic under the foam and it took really well. In fact I couldn't get it off. It seems like the hot glue almost melts and bonds with the foam. So it worked out really well.
It's all one piece but it is very flexible because of the elastic. I haven't painted it yet, but the middle piece has a coat of primer on it and it took really well too.
This is the inside with the elastic. I had to redo some of the straps and ended up cutting them because I could not pull them off the foam.
And this is my dad again wearing the helmet and what I have of the armor so far. Also he is holding my lightsaber that I made a few years ago that looks like I need to change the batteries on.
But for $12 and a heat gun that I already had it looks really good so far. I still need to make the legs and the arms but so far so good. I will hope to keep everyone up to date with this and the film.