War-Machine MkIII Aluminum armor WIP

[TomG]

That is WAY too much shaping for a Dremel. You are going to have to invest in either a die grinder or a Foredom flexible shaft grinder. Even so, you'll need to remove as much material as possible with a band saw.

Have you thought of using fiberglass for those parts? Make a clay model of the part and use that to make a silicone mold. Then just lay the fiberglass up in the mold. You could include metal inserts for fasteners or high strength areas. The molds can be used to make multiple parts.

Tom