Watching this thread closely. I took on the same file as my first pep build and I've never done anything else related to prop/costume building before. My edges have a bit more glue on then yours and I'm struggling a the nose part (mine split open in the middle of the 2 upper triangles).
I guess I'll post a picture in here when I've finally got all the parts together. I've been building in 3 major parts that I'll assemble at the final stage, as it seems just building the entire helmet in one swoop could end up with issues moving it while constructing.
How did you go about it? Are you adding all the little parts onto the mouth part when finished painting?