Ok, so 100% polyester. That's what I've got now, and it's super tough to withstand stretching for vinyl and thick cloths for furniture fabrications. We're also going to try a different stitch length and size, see if that holds up better too. I'd have this costume at 90% done by now if this bodysuit would just come together right for me.
For the time I've been quiet here, I've layered my helmet with resin. I'm hoping to have another layer with the fiberglass meshing done today. How many coats of resin do you think it'll take? I'm guessing about 6 more. I need to look at some threads regarding resin coating and the bondo body-filler coverage so I don't screw this up. I've also been working on making a Bultar Swan Jedi costume for my daughter, and a Jango Fett for my son. My daughter's costume is nearly complete; It just needs two leather pouches made, a black wig, and some brown boots. She needs some for winter anyways. Jango is in progress. I'm to a point where I can place his "armor" on his blue overalls. Armor is silver spray paint covered rubber matt. It's lightweight, flexible, and I'm hoping will take the goop glue. I'm going to have to buy him a helmet. I haven't begun his arm guards.
So, I've been busy at work on this stuff, but not alot of progress to show for now. I have some pictures, but haven't posted them yet. Between the kids back to school and trying to maintain a large garden.. I'm spread a bit thin.