Hi there I am new here and a noob!

[Sir Angus]

You could try a styrofoam head. I know our 'Value Village' stores have them - especially now with Halloween ramping up. They run $2-$3.

Admittedly, I've never tried to do a PEP helmet, but aren't most of those heads pretty small ... Like almost too small compared to an adult head?

 

[fyreant]

So I started a build thread for the suit. See it here: http://www.therpf.com/f24/iron-man-mark-vi-foam-suit-my-160508/

Ant