United Cutlery made a life size, wearable helmet - and RPF member BlindSquirrel made his own, smaller version, as the UC one was ridiculously large. Can be seen here:
http://www.therpf.com/showthread.php?t=32626&highlight=sauron
Hope that helps.
I thought his helmet is gonna be a One-Of-A-Kind-Personal helmet.
Or does you produce more to sell them, Squirrel?
I don't have any plans to make copies at this time. My mold-making skills aren't up to that kind of job plus it would be crazy expensive (for me) to get enough silicone for the job.