I actually thought of this awhile ago. At this point, the one I have already started is not going to work well as far as molding is concerned. While I feel it's fairly accurate as it is, if I were to invest into making a silicone mold, I'd start over from scratch and sculpt it to fix things that I am no longer able to on the current one I have.
However, there might need to be a point in time when I will have to replace the JP regardless. Ive started to notice that connection points where I used the hotglue, is starting to become seperated and no longer as strong as it once was. I will give it a thought. The silicone molding material is very expensive, and Ive been thinking about molding and casting, in fiberglass or plastic resin, the chest piece.
In all honesty, my vac-former has not been doing well as far as collecting dust in our garage, and I would pretty much have to reconstruct more then 75% of it, tweak it out and build a whole new platen in the process. I can do this later on in the future, but I really want to keep the funds towards getting the suit done. I can always upgrade later if it is sub-par IMO.
I'll consider the JP idea, though, help funding the project, Im not really sure who'd want a darktrooper JP lol
-TC