I use Pepakura for all my props and armor now. Papercraft is awesome! I design my models with Metasequoia (sp?) then turn them into papercrafts with Pepakura. I've even made a 3D model of myself to scale my props against, so I have less testbuilding to do to scale things.
Originally Posted by Shouri no Hana
But I'm still a little confused, is there a different way to strengthen the paper craft without using Fiberglass and/or Bondo? I don't have a decent workspace to do something like that (nor the equipment)
Yes, there is another way! The way I make papercraft props is by building them out of single ply cardboard (like the cardboard cereal boxes are made of), then covering them with paper mache. Paper mache takes work to get a smooth surface, but for onesided pieces like armor, you can get away with only putting the paper mache on the inside to strengthen it, and letting the outside remain smooth cardboard.
The great thing about paper mache is that it's non-toxic, doesn't take a ton of space to do (though you gotta cover your work area), SUPER sturdy once at least 4-8 layers are on there, and nothing is cheaper than cardboard + glue +water + newspaper. You can sand it and drill it just like wood, and cut it with scissors like paper.
However, rounded shapes have to be designed carefully so as to minimize the amount of seams and to avoid a blocky look, since corners can't be sanded down like they can when you slap Bondo on top of everything. It's also time consuming to layer the paper on, but probably using and sanding toxic materials takes just as much, if not more.