Here's a shot of the leg cast now that it's off my personage. I took the stuffing out but left the bands on. I'll have to fiberglass over the seam this weekend, weather permitting.
Here's the stand I made to mount my casting on. I got a couple flanges and a 48" pipe from the sprinkler section that had threading on both ends. I cut the pipe down the middle to make two, mounted the flange to my board and screwed the pipe down into it. The T pipe had to be shaved down a little to fit in the end and is still only dry fitted as I obviously need to be able to take it off to fit my casting onto the pipe. Now all I have to do is fiberglass the casting onto the stand, lay a layer of 'glass on my casting and then I can start sculpting. I may need to glue a couple paint stirrers across the underside of the ends of the board to make it a little more stable. It seems solid now but that may change when the weight of the clay starts to add up.
Plaster Cheesecloth Test
We did a little test with cheesecloth and plaster of paris. I had both on hand so I thought that'd be better than buying more plaster bandages. It didn't turn out exactly as planned but I think it might be doable. Maybe mix a little less plaster next time and thin it out a tad more. The test casting did come out pretty darn hard considering how thin it is. I'll be busy for a while sculpting the left leg armor so I won't need more castings right away. Might do a couple more test runs in that time.
I got my fiberglass supplies this weekend. Hopefully this coming weekend will be nice enough that I can try them out. I may look at getting some cloth and mat in bulk once I get the hang of using them.