Would anyone have any idea how to replicate the effect of his visor ? ... i am tearing my hair out. I've tried looking into One way perforated vinyl and motorcycle visor inserts with no luck yet - but neither of these are the same.
http://25.media.tumblr.com/tumblr_m8lmwlzMEx1rdba1yo1_500.png
Any help at all would be appreciated

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Thanks in advance,
Volgun
VOLGUN,
I have never seen the show but I think I can help you,
I worked in designing robitic automation in an air filter production plant, and I would bet my bottom dollar that is an air filter pleate.
if you look closely at the first pic you posted you can see the pleates and the wave of the filter media (notice how the pleates gather in some areas and not others. ( the lines are not parallel ) Trust me, I have seen enough air filters to know im right on this one. think of Laforge on Star Treck.
I would find a large air filter and modify it. kinda like this picture
The first step. I would do is to water down black Writ dye and dye the filter black ( or gey if they make Grey Writ dye) and let the dye dry by placing it pleate side up/ rubberside down allowing the dye to run to the bottom leaving a greyish black filter media.
The next step I would do is to glue the pleate from top and bottom to prevent them from comming apart when you cut the blue rubber (plastisol) off.
( make sure you do this in the same shape as your visor. ) You will need to remove the blue rubber in order to see through the pleates. then cut out shape of visor
sorry did a quick paint but you get the idea. Im not cosplayer and I dont realy make outfits, but I thought about Making Mid Evil Armor for next Holoween
