Actually, a good portion of it is cardboard xD. I just fiberglass over everything to make it look amazing and I work with the cardboard in such a way to trick the look of everything. If you ever need any help, let me know 'cause I'd be more then willing to lend a hand n_n.
I just used a glue and then the fiberglass held it there, and no it doesn't have the same properties once fiberglassed, especially since cardboard will absorb some of the fiberglass in it, changing the cardboard completely, but that's why you'll need a few layers of the stuff.
And yes everything goes through the same stages, molds, patching, sanding, fiberglass, sand, paint. This is an example of something I'm working on which I'm doing that same process with: mypictures.bell.ca/mmps/RECIPI…
I KNOW I knew you were doing some LoL costume but since I haven't played it I didn't know what the character looked like >___< I remember you looked at me and I was standing there thinking it might be you because it kinda looked like you... but having never met you in person I doubted myself Let's hope next time I'm not such a bum. lol