B&Q had some mesh that fits nicely. I've found a few photos of helmets that show a diamond mesh with 4 whole diamonds across the top row of the chin vent, and 6 whole diamonds vertically. With the vent size on the Rubies this gives a roughly 16mm x 10mm diamond size, the Rubies mesh is pretty close but it's cut to fit the diamonds vertically instead of horizontally
I cut the B&Q mesh to match the Rubies piece, and then bent it to fit the face.
I've also got some fine mesh from Halfords that I've cut a piece out to the same size and painted black, this will go behind the larger mesh to help hide the face of the wearer.
So close to finishing this now, just clear coat and then glue in the eyes, mesh, and tusks.
I've also got plenty of spare mesh - probably enough to do 10 helmets!
I got it from the US, was cheaper than from a UK seller even with the postage and import fees. They come up on Amazon and eBay from time to time in the UK but often much more expensive than from abroad.
Not at all. I did sand the plastic using sandpaper first, starting with 240 grit and then 600. I then used 800 grit between each primer coat. Didn't get any of the print coming off.
The JB Weld stuck to the plastic fine, but I used it just to build up the areas as during sanding it seemed to soften a little, and a few pieces came off using the Dremel. I used Isopon P38 (an epoxy car body filler in the UK) over it to give a rigid surface.