Here's the pictures of the display stand I was telling you guys about that I built for my father-in-law at the wood hobby shop on base. Took me about an hour and a half, total.
The barrel is from an LAV-25 (one of the Marine Corps' Light Armored Vehicle variants, of which I am a mechanic), specifically the M242 Bushmaster 25mm chaingun. The vehicle was destroyed by an IED blast, and after it was recovered, we broke it down for usable parts. The gun parts, naming the barrel, were slightly out of whack, so the welders cut it into un-usable pieces. I'm giving this to my father-in-law as a christmas present, something he will go crazy over. His house is like a museum of military vehicle models and pictures.
Anyways, back to the armor. I used 80-grit sandpaper to rough up the plastic on the left pauldron, and bondo-glassed and roughly sanded it this evening. Figured I might as well get a start on that while I'm waiting to make a run to Michael's and Home Depot for supplies. It's stiff as hell now. No problems with flaking, peeling, or chipping from the glass so far. Roughing up the plastic really well is key. It's the 3mm plastic from the garbage can, so it can take some good sanding with no problems.
I did some shaping with the rest of my armor pieces earlier today. I decided that as long as I'm going to be customizing my pauldrons, I might as well do something similar with my chestpieces. I cut and creased the breastplates and belly armor in the same way that I did the pauldrons.
When I come back from my in-laws house on wednesday, I'll get started on bondo-glassing the rest of my armor. I'll be picking up mounting hardware, and hopefully finding something to work as the "flak jacket" or vest. I'm also giving some serious consideration to re-doing my color choices on all of this, how that i've got the ear pieces removed from my helmet. As long as I'm using my tan flight suit, tan nomex gloves, tan neck gator, and tan boots, I might as well go to more earth colors and make a desert mando.