General Overview

To get a general idea of what to expect, a project such as a full suit of armor could cost anywhere from $200-$600; and a sword could cost $100-$200 just in materials.  Most of your time will be spent in the sanding stage if you want to have a nice looking prop; as the fiberglass and sculpting stages are rather quick if done right.  The overall time for a suit of armor could run about 200-600 hours depending on skill, size, tools, and desired results.  A sword could likewise run from 50-100 hours depending again on the desired results.
            The optimal working conditions are low humid areas with a temperature around 70°-80°.  The hotter it is though, the faster it dries.  Working in a well ventilated area or outdoors is a necessity, as the smell is very potent.  A respirator is highly advised.

Safety Information

Liquid resin is known to have cancerous materials
Pink foam is toxic when burned
Fiberglass dust is very itchy and may cause a rash
Most of the materials are highly flammable
Some chemicals can be absorbed through your skin

Prices/Locations

Most materials can be picked up at Home Depot, Lowes, or Marine stores
Purchasing larger quantities is much cheaper in the long run

Polyester Fiberglass Resin (gallon): $30
Epoxy Fiberglass Resin (gallon): $100
Fiberglass cloth: $5
Foam sheet: $12
Sandpaper pack: $4

Respirator: $30
Power Sanders: $50-$100
Dremel: $50-$100

Materials/Equipment

Foam
Hot glue
Epoxy Resin
Polyester Resin
Fiberglass Cloth
Acetone
Bolts
Paint

Gloves
Goggles
Respirator
Long sleeves

Files
Saws
Dremel
Power Sanders
Sand paper: 60 & 220 Grit

Types of resin

There are two main types of fiberglass resin: Polyester and Epoxy.  Polyester, commonly found in hardware stores may cost less and dry in about 15-30 minutes, but destroys foam.  Epoxy resin, commonly found in marine stores cost three time as much and dries in about 12 hrs, but doesn’t melt foam.