Hope you find at least some of that useful. This soaks in, temporarily loosening the glue in the corrugations, allowing the sides and corrugations to move slightly to accommodate the new shape before drying in the new position. After bending a piece of cardboard (hopefully without kinking), wipe both sides with a damp (not wet!) cloth. setting enabled in Advanced Options) also makes other Pyroland items visible. One other trick I learned with cardboard. The nine hats introduced were the Batters Helmet for Scout, the Soldiers. The paint waterproofs your parts and soaks into the fibers, stiffening the parts significantly. Anyway, paint your costume parts inside and out with the oil paint. Those are water based and will dissolve the glue inside the cardboard corrugations. It smells awful, but you need the oil paint rather than acrylic or latex. See if you can find to surplus oil-based building paint. On a separate note, I did a couple of things to my armor that helped its longevity. Not sure if something like that is available where you are, but vinyl wall spackle might be.
I used a craft sculpting product that was a mix of paper pulp and clay.
If you decide to try a filler again, you'll need a flexible filler that won't crack when the cardboard flexes. In an earlier post you said that you had tried Bondo, but that it didn't really work out. Your cardboard work is really impressive.
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