After a little score and snap, and a little trimming up to the original line, the fit was pretty good.

I then placed the cardboard template against the ear, drew and cut. repeat for the side of ear. I love my curved Mayo scissors. Rescued them from recycle bin at work. Benefits of working in the operating room.

next, I cut out the cardboard template and fit it to the helmet.

I thought up a different way to measure and cut my ears. I wanted to be a hotshot and get them right on one try. At least that was the plan....... I got some thin aluminum pieces and cut them to size. I laid them onto the helmet where the ears would touch them, then put this on a piece of cardboard ...

http://www.whitearmor.net/forum/topic/2 ... ild-82014/

Here's my link to the build over at FISD.

let me know if this works. I'm pretty much duplicating this build thread here. Helps to get hints and tips wherever you can!!

Hey thanks!! You're the first to comment on this. I have made some minor adjustments since this post. I was seeing that people were viewing but I haven't got any comments. I will definitely keep posting as things progress. I should get my ATA box in a few months (been since April and there's a 7 mon...

There is precious little material to rivet to. It's kinda stresses. Is there a danger of this stressing, cracking and popping? It's 2mm material and pretty strong, but I am concerned about long term. I thought about taking a heat gun and standing about 10 feet away and getting closer about an inch a...

so here is the progress. looking like a helmet. i screwed it together with screws and washers the same size as the rivets so I can get some feedback before I do it for realz.

I have begun my helmet build. It's above in this forum under "TM Hero Helmet Build". Everyone feel free to browse and critique.

I have begun my helmet build. It's above in this forum under "TM Hero Helmet Build". Everyone feel free to browse and critique.

I have begun my helmet build. It's above in this forum under "TM Hero Helmet Build". Everyone feel free to browse and critique.

So here's the big question. I may have to pop rivet the begeezers out if this to make it stay together. I've clamped and magneted it and it's awesome, but as long as it's covered up will it affect acceptance??

Another gap pic from other side. Is this normal? Will ears cover this? Ears are hard enough to get right.

Overlap is sparse. Will this close and be covered by ear?
And this one?

Making magnets finish friendly with blue masking tape. Gotta keep them separated. They don't play nicely with each other. mags.jpg Looking like a helmet now. Magnets and clamps for trial fitting. Doesn't go together seamlessly. Work to be done. mrlowbrow.jpg Gaps. Is this normal? It has barely enoug...

More filing of teeth. I think I'm done for realz this time. Comments?

second pass at teeth, eyes worked on a little more. I think I'm done. may take a whack at assembly tomorrow. Taking any critiques.

Other eye done and first pass at teeth. I want the "twinkie" rounded look but I think I need a little more trimming. The ones on the right I think are better? Thoughts?

Here are prelims of trimming. First pass at eyes. Let me know what you think. I think I need to open the eyes up a but but I don't want to go too far. The bubble lenses kinda roll around a little in the spaces, they don't sit flush or tight. Is this OK?

The kit is awesome. I think it has everything I need. It's off to the craft and hdwr store to get some tools. thanx to Seekandestroy for the pic tip!!!