Expanded cell PVC foam board has got jillions of little air pockets inside of it, so it is much lighter than solid PVC pipe or sheet. It's very workable, bendable with heat, and it's pretty cheap. It's much cheaper than solid PVC because there's airspace in it. I go to a local plastic supply place, the sort that would provide materials for a sign store, and buy it by the sheet. I haven't made Fett armor, but from the R2D2 stuff I have built, I'd feel totally comfortable shaping some armor from it. Comes in all thicknesses. I go to Interstate Plastic Supply here in Sacramento. Interstate Plastics