I just read through this entire thread... again. Amazing what one man (and friends) can accomplish. Thanks for the recommendation of that book, too, it'll definitely help me get into moldmaking. Loving your digital camo, by the way.
I'm also interested in your visor setup, as it seems like it's a lot more customizable than motorcycle visors (and potentially a reasonable solution to the full-visor EVA and such). Not to mention I really like the slightly bubbled look. To get the reflective finish, you're spraying a very light layer of mirrachrome (or was it a different brand?) through an airbrush / paint sprayer, correct? Any additional details you might be able to give on this methodology?