watch out for that tree

I assembled a scout trooper helmet off my printer and learned a lot that cold make the whole process easier on the next attempt. My main problem is how inaccurate the file I used is. Its primed and sanded but it might end up a neon color with leds as a spoof party costume opposed to a cosplay. Which is why this shoretrooper build excites me. I have no idea what trooping actually involves but I have seen 501st at events and dreamed about joining. A trooper costume just seems better with friends to help cause shenanigans.

I kind of want the project. I have no experience with casting like that but it seems doable with practice. And like you said the fit and detail would be up to the quality of my work. It really isn't about the money, more using my 3d printer for a big project. But I was wondering if anybody could give me an idea of the magnitude of molding materials necessary for a full build. I just don't really have any reference to base estimates on. What are your thoughts on an accessory kit like this? I know that the last step in what I'm planning to do but just wanted your opinion.

What about molding and casting pla parts. I know pla isn't the best choice for finished armor for a lot of reasons, but I can print and assemble my hard pieces for pretty cheap. Would the mold and slush cast for a set of armor be too expensive to be viable? I would assume resin armor would be light, durable and easy to finish compared to pla. I know this wouldn't be easy but a few symmetrical parts could be cast twice to save some work. I want to start my first build with these files. Any tips appreciated.