Thanks for the kind responses! I used mostly pepakura for all of it (and resin/bondo of course). was my first time using pep/resin/ or bondo though - it seemed to come out all right. for the detailing I made templates and cut the shapes out of 1-3mm styrene (for sale signs and trash cans =P). The aged gold look is just brilliant gold, sanded down a bit for an aged look, then wiped over with some black acrylic.
This has been a real fun project =P
I had a hell of a time collecting the pepakura files I used for this project though, I am not sure why they were so hard to find. If anyone else has any desire to start a project like this or wants to use the pep files. I uploaded my collection to rapidshare. I think its about 3 full sets of different kinds of SM armor and a ton of unfolded weapons. There are a bunch of just 3d models of weapons in there too if you want to play around with those. Hopefully it helps someone.
http://rapidshare.com/files/408543879/Astarte2s.rar.html