I went through a lot of car filler, sanding it from 80 grit to 600 grit sandpaper to get a good surface. The resin and fibreglass strengthens the paper model, and the car filler allows us to build up the outside shell, hiding the paper corners/edges and sand it down to a smooth surface.
Fibreglass resin, fibreglass matting or cloth (I found mat to be stronger but harder to apply neatly, and cloth the inverse), resin catalyst to cure, and car filler (often referred to as Bondo). I also used a cheap rotary tool and a small 1/3 sheet palm sander to sand everything down and to dremel in details. I used some latex-free gloves (latex can mess with the silicone molding supplies), dust masks, and safety glasses. Some safety supplies for when you are fibreglassing/sanding/painting everything up. Basic hobby glue, an Exacto knife and plenty of spare blades to cut everything out. I used a file for the helmet done by a person called Rundown from the 405th forums, at the time it was the most accurate file available for free. You can then cut out the individual pieces and glue them together with plain PVA glue. Basically it takes a 3D model, splits it up and formats it to be printed onto cardstock/paper (I used 140gsm paper). A program called Pepakura Viewer/Designer. This is a somewhat lengthy process and to do it the way did you need a number of supplies. Edit: I realise that I've forgotten to put up sources for the Helmet and Suit files, here they are: I was able to get it done well before the premier night and was able to build a quick foam suit to were with it, I didn't originally plan on making a suit so I don't have many photos of that build process, but there are already several tutorials on this website on making cosplay with foam. I planned on posting the whole process on here, so there are lots of pics to help you all out. I used the free files released by a 405th member Rundown for a base (not sure where to find the original anymore), and have strengthened it with fibreglass, sanded it down with car filler, and created a reusable mold using silicone products and cast a final product with plastic resin. I really wanted to make one, and fortunately some lovely 3D designers on the internet wanted them too and released a number of 'blueprints' for paper craft. Several months ago the the trailers for Episode VII were released, and a number of the new character designs were revealed, and what stood out for me were the redesigned Stormtroopers belonging to the 1st Order.
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