Hey Nick! I just sat down and read this ENTIRE thread. I made a huge list of all the stuff you used and I'm taking my armor-making style in a whole new direction. After all of this I have a few question:
1. After you cut out the foam pieces from the pep files, do you still keep the tabs and fold them to glue all the pieces together like you would with paper?
2. How many layers of Bondo did you put onto your helmet?
3. How did you fasten your visor to your helmet?
4. How much will you charge for your Mark V helmet unpainted?
You have been a massive inspiration to me and I'm so glad I stumbled upon your thread. Keep up the FANTASTIC work and congratulations on the new team member!