I wanted to wait till I read through the entire thread before asking any questions. Turns out, no more questions! And while reading through everything, I put together the Vanquish ARS helmet. I never played the game, but the armor looked hawt.
I sized the helmet wrong, which was 100% my bad, and it ended up being quite large. My son liked it regardless and I decided I'd finish it for him.
Since it was a test build to see if I could move forward with a future project, I wasn't worried about the unevenness in some places. I learned a lot, being it's a complicated piece, so it was an overall win.
Harbor Freight 1/4 inch diamond print EVA mat. Considering the helmet being oversized 10% for my already oversized head, it wasn't too much foam.
After assembly, used my soldering iron to do some detail work.
Glued the strap on one side, magnet on the other to make it detachable and have room for my noggin while pulling it on and off.
Painted with white glue and white Plasti Dip
Stretched some Spandex/Lycra type material over foam pieces for visibility.
Painted in the lines and details, and dirtied up the plasti dip with acrylic paints.
It went together without too much going wrong. I'm still debating how I want to handle the mouth visor (so my mouth can see) because I'm afraid cutting out the foam in the visor spot will change shape of the helmet all around, so I think I'm just going to spray some Krylon mirror spray paint on the inside of a blue tinted notebook folder and glue it right on top of the foam. A little more weathering and some soft foam inside for support is all that remains.
Very fun build. Thanks, JF.