A look at what is currently available on eBay
 TAG TKP353 Volleyball Kneecap Knee Guard Pads White - One Size Fits All US $10.97 
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 ASICS ZD09 Volleyball Kneecap Knee Guard Pads Red - One Size Fits All US $7.97
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What is the best system for creating and casting molds for large objects?
What product is best for creating molds and then casting them in resin for large objects? I am working on a prop armour suit for a Con next year and most of it will need to be custom made. I have all the plans worked out but wasn't sure which system or brand was best for molding and casting large parts (such as shoulder pads, forearm guards, and thigh guards).
And i am on a sort of a budget, so i dont have the money or capability of vacuum forming.
All help is appreciated!
In the world of sculpture, those are not large objects, and I have to question whether resin is the best choice for the items you name - fiberglass or one of the heat formable plastics would seem to be a better choice. In any case, normally for medium to large cast sculptural objects the original model is normally done in non-hardening modeling clay, which can be reused, and from this molds are pulled for forming copies. The copies may be plaster, plastic, etc. The mold may be rigid plaster if made in sections or flexible material the least expensive and least strong being latex molding compound, which has to be backed with plaster to hold its shape. This link http://www.horsesculpture.net/studio.html has a video that show a very large clay model of a horse in soft clay and the making and pulling molds using rather expensive silicone to make waxes for lost wax casting. This link http://www.mikegigi.com/modeling.htm shows my page about latex and clay on my website