Help - Iron Man Foam Helmet

Thanks ahead for any suggestions.

I'm staring on an Iron Man build. I have the peps, the foam, and have done a few tests cut-and-glues. I am finding that when I use 6-10mm foam, I am having a devil of a time with the helmet. And suggestions, such as "build order", "foam thickness" or "part re-sizing" for the helmet. It seems I always have pieces out-of-scale (such as sides that are too large/long). Right now I'm just experimenting so I'd love to get suggestions from those who have already tackled the costume.

Thanks again! :facepalm

i used 2 mm foam that i doubled up when needed.

i used 1/2" for sides and rear and 3mm on top of helmet and face plate you can check it out on my thread. Shows that foam helmet doesnt have to look like foam helmet

i can second that, you wouldnt know mine is foam

I used 10mm for my helmet, using JOWEs foam files for sharkman's helm... (http://www.therpf.com/f24/robo3687-iron-man-mark-4-6-pepakura-128147/) I dont have any particular tips, just to combine it into as few pieces as possible, and cut the detail lines in afterwards... It seemed to work for me...