Hmmm there were only about five or so hero Borg costumes made for First Contact, was there one in particular you are trying to reproduce?
Well see I'm planning to put electronics in the side, and for the eye some of the Borgs had a holo thing for the eye. I'm actualy thinking of re-doing the eye now that I look at it though.
is this going to fit your head? then you might wanna make a cast of a real human head before building the eyepiece.
I'm planning to only make the eyepiece right now, planning to do the rest of the headgear in sections later.
When I built a Borg costume I used a kids spy toy headpeice that had the red laser that was mechanized (cheaply) and a halogram like mechanized peice that would move down the side of your head and then would drop in front of your eye.
I attached a flashing led to the eyepeice and some reflective tape and I had my Borg halogram! Cost was $25.00 for the spy toy and $5.00 for the led and tape.
Here is a close up pic of the spy toy modified with led's and automotive wire.
that looks great rb