First time building is a struggle.. I have learned alot from building my first Mark 5 build --->
http://www.405th.com/showthread.php/36202-Upgrade-on-Mark-5-full-build
Hopefully you can find helpful hints in there.. ( the fiberglass / rondo way your doing will take longer )
* Fiberglass/Rondo builds in my terms "Better, more detailed, more time consuming, more costly, and overall more complicated."
* Foam builds in my terms "Never as good, can be really detailed or simple, can or can not be time consuming, SUPER cheap, and overall more simple."
Rondo can be very heavy.. I used foam for my chest and waist, I could not imagation how heavy my chest would be if it were fiberglassed.
Your build so far...
-Shoulder pieces are alittle big, and they are extremly hard to fiberglass and rondo (they want to bend and fold all together when your fiberglassing them.) So best of luck to you when you try to fiberglass them.. I have never got good at the Cloth/fiberglass --Rondo is the way to go! (Rondo is 4/5 cup Bondo and 1/5 Resin liquid)
-Your chest plate being big is normal- Mine is alittle big, but remember you have to put it on..so strapping system is a must. I slide into mine like a turtle... its not fun, but its foam and bends alittle.
-Liltyrant may could help you with undersuit problems, she custom made hers, but for us less talented in the sewing department--I suggest *TMS motocross Suit*** this gets alot of looks and questions what it even is... (Longshot wears this during the summer, its nice and cool. It will also take up alittle extra room inside your chest plate..*
-I thought about a morph suit, but they would get hot under that helmet of yours! Plus fog in your visor will become a problem later on... Everything your doing looks great! Your pep files are a A+ ... Remember do not add much bondo to the outside of your armor- try to fiberglass it good without warping the piece.. The more bondo on the outside of your armor the more sanding you will have to do later (detail work)...Dremel is a must if you are going the fiberglass/rondo way too....
***Words of wisdom from 405th member I always remembered.... "With enough bondo anything can be fixed" -sadly bondo cost alot 20 bucks a gallon... I used about 3 and didn't bondo my waist belt or chest...
DREMEL I HAVE----
http://www.amazon.com/Dremel-300-1-...TF8&qid=1361891270&sr=8-1&keywords=dremel+300
DREMEL TOOL MUCH NEEDED I LOVE IT---
http://www.amazon.com/Dremel-225-01...TF8&qid=1361891270&sr=8-5&keywords=dremel+300
I love Rondo way of making armor, because you can add bondo (sand and add Detail) or if you mess up, simply sand it off and add bondo here and there... easy fix just takes ALOT ALOT of time.
Foam is different because you can't take away ( you can only add to ) You can't really sand foam down or cover bad places up. You will have to add more foam on-top of to hide it... Layering foam...
So I just wanted to throw all this at you because, I wished I had alittle more insight when I started my project... If you have any questions- feel free to ask!
--I'm currently working on a 2 Kat suits for my wife and her best friend... also making Iron man masks and selling them as art =P
-Nogood