I got a bit of work done on my helmet, so here is some updates on that.
Currently Looks like this
I found that 1 Layer of cloth around the whole helmet would sufficiently harden the piece. Then around the openings (neck and the lens area) I added a layer of mat. This gave the durability that I wanted and kept the part from flexing almost completely. There is a spot on the top that I will reinforce with some mat tomorrow but for the most part it was fine.
You can see the cloth here
And here is the effect of the mat, you can see how thick the fiberglass is around the edge and it helps a lot.
I have a little warp in the pep here and it was made permanent in the fiber glassing stage but I figure I can sand it flat.
How I will be padding the helmet
And most importantly how it fits for scale
For the raised surfaces I am trying to decide what to do, and I am looking for high quality and cheap. My best though right now is to get some 1/16th or 1/32 inch balsa wood and glue my template onto the sheet with a spray adhesive, then gluing it down and painting on some resin to harden it because its a very soft wood.
If any one else has some input on a way to give nice clean raised surfaces I am all ears.
-Largo