I like what you got out of the helmet, I've got myself a stony props helmet too.
Package already arrived but is currently stuck in custom clearance, damn stupid custom clearance is taking ages.
Can't wait to have this "i can't believe i own this" moment by myself, even 'though it's not a "i can't believe I totally made this on my own" moment ^^
How are you doing with the CoolC templates? Any problems, easy to build?
CoolC has made some, Rhinoc has designed some foam templates with little details on purpose, but easy to build, and last but not least I have tried some foam unfolds too. You should check out all of them.
Oh, sorry. I'm using Krylon spray paint for every color. And for the detail/ clean-up/battle damage I'm using black acrylic (not spray) and a detail paint bush.
yes, like dash said, it is an orange bubble visor that i got on ebay. its not mirrored so i sprayed the INSIDE with a very thin coat of silver spray paint
No, it won't burn the cardboard, though it'll burn the edges (that's what a lasercutter does ) but since you're applying bondo and paint anyway it really doesn't matter afterwards.
I don't know if google sketch-up would work, depends on the format you are exporting to. I'm not sure what format is required, but conversion shouldn't be much of a problem.
Edit: May I asked how tall you are and what did you scale the torso to?