RPF PREMIUM MEMBER
Great history!OK, some info...
1) The original Don Post Stormtrooper bucket from the late 70s (mold was re-used throughout the 1980s and even early 1990s, I believe) appears to be a custom sculpt. It's a little long in the face, and small. I believe that the rectangular holes in the ear caps were intentionally there to allow kids to hear through the helmet. The ear caps were later covered with round, gray foam pads on the outside of the helmet.
2) The helmet sculpt was decent for its time, but not screen accurate. It was eventually replaced by the Classic Action vinyl Stormtrooper and Don Post Deluxe fiberglass Stormtrooper helmets (both of which used the same, left/right half mirrored ROTJ mold as a base). The same classic action mold was used for the static Don Post Stormtrooper statue, but without real "lenses," the statue eyes were solid and painted black. )
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3) The original 1970s Don Post helmet appears "squished" front-to-back (when viewed from the side), and reminds me a lot of a smaller version of Altmann's Australian licensed Stormtrooper helmet below:
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4) TheRPF member FalconV8 recently did a NICE conversion of the DP bucket. Click the link below for pics!
1977 Stormtrooper Helmet Don Post 20th Century Fox can actually look kinda good..!!??
5) The original bucket from the late 1970s had lenses... later versions in the 1990s had solid eyes with multiple holes drilled through them for vision (probably for cost savings)
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6) Jez's excellent StarWarsHelmets.com site has some nice pics and info. The Don Post Classic Action (based on a mirrored left half/right half ROTJ bucket) in on the left; the huge GF/White Sunblock bucket is in the middle. and the original 1970s Don Post mold ins on the far right.
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Head over to his site for more info and pics.
And as for my 2 cents? I say restore your helmet as much as possible to it's original 1978 form!