Awesome!
For the longest time, I've been wanting to do my own helmet, but with a different take than other people who do one. most will want to make a screen accurate version of ANH Hero Helmet, or a RotJ Stunt version, or whatever.
But I want to make one that is
universe accurate (or as much as is possible anyway).
In other words; most helmets incorporate the screen versions' abstractions and simplifications because the filming process did not require minute detail. Also, budget and time were obvious factors for the films' prop makers.
So I wanted to get a shell and cut out the mouth, to replace the grey bars with actual metal strips for instance. And the grey shape on the cheeks/sides of the face should be small, perforated plates, as opposed to grey stickers with a few black lines.
Because this is a fictional piece of equipment, some interpretation and imagination will be required. What is the purpose and function of all elements? Then, each element has to be approached with that in mind. And then the parts will get a life of their own, as opposed to just being decals or stickers on the surface.
By the way; I always saw the blue lines on the side tubes as some sort of vents as well, but rendered as blue lines on the movie versions because of the abovementioned reasons. Also, they may have been added just to break up the white of the surface for filming, adding some interest.
It's just that I cannot find any sensible in-universe reason for those lines to be there as painted-on lines...
Anyway; your helmet project looks like it will create a version that would support my take on a universe-accurate helmet perfectly, so I'll be following this thread with a lot of interest!