And here we go! (Volpin Thomas build)

[Dei]

http://www.chrometech.com.au/

Here's their site! They've been pretty helpful thus far.

Thanks for the tips guys! I'll probably attach a support in the middle once I've bought my plastic for the visor. Will be trimming a little more off the edges and mounting it from the outside, just to give me a bit more vision.

Also started looking into the intake fans that I'll be installing over the nose holes. Found a few that are normally recommended for Stormtrooper helmets, and I think they should work fine!

[something awesome]

Will you be removing the supporting section from the middle of the visor eventually do you think?

[Dei]

Honestly depends on how much the front would warp after I install the visor. Even now, I've put a thick block of foam in the space that I cut out to support the top and bottom half to prevent warping, following some advice from Volpin himself. Apparently the early casts were prone to doing that after a while, leading to permanent deformation.

[PedroAloha]

I have fans in my stormtrooper helmet, you can buy the CPU fans prewired and everything on ebay, just add a 9v battery and you're good to go.

[Dei]

Do you have a link to some that would probably fit in a Thomas helmet?

[Dei]

Question for anyone who has worked with a Volpin/Firewire Thomas before, how are the ears normally mounted? I've got them with the little cardboard rings that Volpin inserted, but I have no idea which section to add the glue to before attaching them to the helmet.

[PedroAloha]

Just type CPU FAN into ebay then take your pic of helmet sized fans

[Dei]

I managed to find some for sale at a local electronics store that would fit perfectly into the nose area

[Dei]

Here's the helmet as of now! Primed, sanded, ears have been fully trimmed and fitted (ready for gluing)! Gonna give it it's next coat of primer tomorrow.

For the visor, would 3mm clear acrylic sheeting work? http://www.jaycar.com.au/productView.asp?ID=HM9509

If so, what would be the best method for prepping it? Cutting shouldn't be a problem, but I'm not sure on which method to go with to curve the visor. Heatgun? Boiling it in RIT dye until it's soft enough to be bent? Putting it in an oven until it's soft?

Argh, so many options!

[Crank729]

3mm is way too much for a visor. Even thin acrylic is a pain to cut and shape, So I wouldn't go any higher than 1 mm. I use a heat gun to bend acrylic, but you have to make sure you get even coverage or the acrylic will bubble.