Just thought I'd ask....have you ever been to Mood here in L.A.? You mentioned Joanns and the fabric district but Mood tends to have some AMAZING fabrics to choose from if you haven't been. There's also F&S Fabrics in Santa Monica but they're a bit more expensive. Also we made our prince nuada armor out of wonderflex. I highly suggest getting friendly plastic to cover the wonderlex in to give that smooth armor look. When we did nuada we covered it in gesso like many suggested and even after days of painting it and sanding it we still didnt get it completely covered and the gesso does chip if you're not careful. But other than that we were really happy with how his armor turned out....we were even able to get the weird spine knobs on the back of it. I know the costume is on hold for now but just something to think about for in the future if you haven't already.