Aloha, welcome to the 405th! If you're looking for templates, check out the
Armory. Which version (AKA Halo game) of Caboose would you be looking to make?
For getting an estimate of foam, have a look at our
foam guide here (I've specifically linked to the post estimating foam amount usage).
I don't have very much experience with visors, but I have made a simple one using a PETG plastic sheet and reflective window tinting. I used window tinting because I'm limited to what I can get in my country - you may be able to get reflective spray paints instead. Alternatively, have a look at something like the
material IconProps sells. If you want your visor shaped, you'd be looking at the vacuum forming method. You can do this yourself, or alternatively, find someone who sells those specific visors/is open to commissions. Sorry about the sparse info on visors, I'm sure somebody can help fill in the gaps.