I finally tried foam floor mats instead of cardboard for my Mandalorian armor build
Spent $12 on 4 packs of those puzzle gym mats at Five Below instead of using free cardboard, and the difference is night and day. The foam holds heat from a heat gun way better so the curves actually stay put instead of flattening out after a day, and it cuts cleaner with a box cutter too. Anyone got tips on sealing the foam so spray paint doesn't eat it?
Feel that pain on the cardboard flaking apart after you already put hours into shaping it. I went through the same thing with my first build and wasted so much time redoing pieces that just would not hold their shape. The foam mats really do change everything, and I wish someone had told me sooner that a few thin coats of plasti dip works great as a base before you spray paint. It gives the foam a skin so the propellant in the paint does not melt it, and it stays a little flexible so it will not crack when you move around. Just do light coats and let each one dry or you will get drips that look awful up close. Also hit the shiny side and the cut edges, those edges soak up paint like crazy and will look different from the flat parts if you skip them.