Cosplay Armor Material I Can Spray On?

I seem to be a bit of a pickle. I've made a giant (wearable) armour suit, however it is currently made from a thick paper (Hurray PepaKura) that will simply not endure the wear and tear of taking it somewhere, nor what the weather may bring.

I'm looking for something of a spray-able plastic or rubber that will leave a sturdy and hard layer on the outside of my armour, while at the same time hopefully waterproofing it. In the worst possible case, i'll settle for Poly-urethane foam on the in/outside, but i'm actively trying to avoid the cruel fate of having to sand down my armour for weeks after having applied the foam. I have used Acrylic Gesso in many many layers in the past to make masks sturdy, but i believe it would require too much of it to finish and would make it far too heavy in the end.

I think that fibreglass in a resin may be an option, since i have some on the shelve, but it would leave me with a very rough surface, not to mention it's quite tricky to work with. Unless someone can name a spray-on fibreglass.

If you have any suggestions for what i could use, i would love to hear about it.

Some criteria:

- Sprayed or brushed in a thick layer, lets say 5 mm to a cm.
- It has to make it more durable or hard. Enough to last through 3 days of hug tackles, shoulder pats and whatever the weather may bring. Flexible thick rubber as an outer layer seems ok too.

Much obliged,

Suri

You could try plastidip which I think is plastic or rubber spray ive seen it in amazon but ive never used it and its black. It does say though that it waterproofs anything and can be used on anything. You could try resin though if its too thin it will crack/snap to a "playfull tackle" but it will be water proof and dries clear. Theres also paint on latex that ive used for a few wearable pieces of art at uni... nothing kinky... it *** stinks till its dried and you can layer it up making it stronger you can add colour to it as its a creamy colour and its cheap.

What about truck bedliner spray? Mythbusters made a body armor suit thing out of it that stood up to attack dogs.

also in white, your friends can use you as a lifeboat...

I've seen the bedliner on mythbusters too. It was one of the first things i checked out, and it's actually available in my country as well. The downside is that it's cheaper to import it from the US (Where it's still easily $120 a can outside of $40-50 shipping), than to buy it locally. For just a hobby, i'm not looking to spend $200+ to coat maybe one piece of armor with it without knowing how it'll look.

Flex Seal we should have here too, and it's not too expensive, but i have no idea on the properties of it. I saw the (horribly anoying) ad on their website that it's basicly a spray-on hover dam... which didnt tell me a single thing about what it did, at all -_-

Plastidip seems amazing, and at $12,50 per set i'm definately grabbing some just to try it. It even comes in Silver so i dont even need to repaint it.

Few more alternatives would be greatly appreciated though ^^

Good luck on your piece and hopefully you'll share some pics of the finished product!

You can get this clear flexible sealant from Home Depot:
http://www.homedepot.com/buy/rust-oleum-stops-rust-11-oz-leak-seal-clear-spray-265495.html#.UQiiRPJp90Y