I GOT IT!!!!!
First, i wana thank everyone for the feedback, all the ideas and talk really helped me open my mind up to new ideas. SO after reading and watching enough pepakura vids and tutorials to make my eyes bleed T_T I came up with a method of making decent looking clone trooper armor with out spending a fortune and without having to use major plastics and stuff. NOW im going to star a new thread, and i have pics of the work in progress that will be up soon. thanks again for the help and ideas.