Was the visor too small because the sculpting head was too small? I had that same problem a long time ago. I just thought they were all pretty much close to human size, but of course...that's not the case.
I know this was years ago but I wanted to make this costume. Trying to figure out how to make the belt and chest straps. Did you use foam or did you use an actual strap O hold all the pouches as well as the chest strap