First off I'd like to give a general warning about the pep file; The helmet you see here and the original file look nothing alike. The file provides a good base to start with compared to shaping everything from scratch. I had to print the file twice on diffrent scales and then cut and trim it to get it to an acceptable shape, and most of the final shape was achieved with bondo and wood, hence the reason I needed to cast it to make something wearable. In otherwords no details of the pep file should appear on the final product.
As far as damage on the helmet there are two sources. The pepakura file is not 100% symetric with the folds causing some sharp ridges in some spots and valleys in others. Additionally, the file did not have any supports and I used a manaquine to support the paper durring glasing, so the final helmet unintentionally does have the apperance of being dented and bent in a few locations. Additionally, when I smoothed the helmet I left a few depressions unfilled (i.e. I limited the number of bondo/sanding cycles) to give the impression of dents. The nice thing about this project is that the suit needs to look like big things have hit in and the imperfections give it the desired look.
The other source is Dave and I did add other imperfections, cracks, and scratches into the helmet during weathering to give it a true warn our look.
As far as progress goes, The drill is painted and off at weathing right now where Dave will be adding all the blood, grime, and meat to the drill. I've also started the "Flavor Flav" weight and we are planning to start the dive suit tomorrow. After the suit is made I can start focusing on the remaing hard details as well as the little sister syringe. Stay tuned.