/cgl/ - Cosplay & EGL

I need help, Metal Gear RAY... I've seen Volpins big daddy tutorial where he uses cardboard and insulation foam with fabric but the part that kills my budget is the fiberglass

I'm wondering if there's and alternate material/coating to do this- I was considering polyurethane and heat gunning parts into the correct shapes over a PVC frame as well as cardboard base with EVA foam and mod podge to seal (this has worked well for my armor type cosplays/accessories in the past)

There was another big daddy who said he used Bondo but that hardens to really hard material and is heavy over large areas...

Thinking of making digigrade stilts too...

I want to also make this able to break into sheets/pieces since my car can only fit so much