Well! A weekend's work put a big dent in the suit. After much hack-sawing and box-cutter butter blading (my term for the smooth cuts made by a fully extended box cutter blade), the shape is really coming through.
First rough shaping pass:
The above is mostly hack-saw work, then the box cutter to trim down the waste rim:
The back needed some treatment as well, getting it closer to flat:
This is where this tool became my best friend:
Using the belt sander and a hand sanding sponge, the torso began to take shape. I also used the box cutter to start to shape the rims of the helmet and arm holes.
It was very difficult getting them to be perfectly round after all the sanding and shaping and cutting, which is where the next step helped a lot. Using a different grade of styrofoam, cardboard rimming, and very stick masking tape, I shaped the helmet and arm rims to be properly circular:
Wooden dowels held the circles in place. And the back:
So there you go! It took a bit of reshaping and eyeballing, but it's almost there. Another night of precision trimming and probably some card stock and more tape will get the shape ready for curing and fiberglass. Just a little context of the workshop and the mess involved:
More to come soon!