Did you just want the floating faces moved out of the way or completly taken off?
Actually Scratch that, I got into working with it and made significant progress. I'll probably release it later tonight, Thanks though, For future unfolding references, You could probably move them a bit farther out.
Wait, There are quite a few open edges on it though, Forgot to mention.
Update!!!!
I got the unfold done, kept it pretty symmetrical. A few confusing spots i'll admit, but I tried making it as friendly as possible (since i'm gonna use it for my own costume) So here it is:
http://www.4shared.com/file/EfNhp2Ln/Sd_H4_Helmet_by_harnor.html