I hope you don't mind but I refolded your amazing file to work for foam for those of us who are foam-crazy.
http://www.4shared.com/file/jV3128w5ce/90s_Cyclops_Visor_foam.html
45 cut any of the pieces that have a split in the actual template piece so you can get a bend to that piece in the foam. Any pieces that are solid you just wanna bend the foam with a heat gun to shape the helmet the way you want it. Check Pepakura Designer for help and if you have any steep...
I'm working on a Medieval Dr. Doom foam costume after Shinobitron's amazing medieval Dr. Doom action figure on deviantart.
I had a lot of trouble with bondo + pepakura, and being on a budget, left me doing most of this costume out of foam which has turned out really good so far. I've completed...