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I have been working on a wee project for the last couple of months, basically a helmet about the size of the original riddells helmets but for the AT AT and Tie pilots to start with.
Pictured is one of the better renditions of what I have been working on.
I have also made up a helmet for vac forming, in three parts to allow for taking the formed plastic off the form.
These have been made out of builders bog, basically a solid piece so lots of carving, sanding and re bogging.

hey badges that looks great nice work! looking forward to seeing the progress

That looks excellent

Very cool

Thanks guys, I have been working on two of these.
One as in the first picture to do a glove type mold with silicone and the other one as a four piece suitable for vac forming.
The main reason for the two is that i can immediately cast from the glove mold, later when I get things sorted i'll do some vac forming to do an up market helmet with visors frown mesh and interior lining like the EFX and MR helmets but minis.

Looks really neat.

what gauge plastic are you going to use? I reckon as thin as you can get so you can pick up all the detail nice work dude!

I'm not too sure on the gauge plastic, Vac forming is going to be a totally new thing for me (VIRGIN).
I figure that I could do three different helmets out of this one, AT AT Tie pilot and possibly x wing.

That's cool man its great trying new things!!

I reckon styrene might be the way to go and maybe 1mm or 0.5mm given the size of the object. Anything thicker you'll lose way too much detail IMO.

good luck!

It's always good to get advice and feedback on how things work out and what to do, Thanks Oota and every one else for your help out there.