I made my helmet, but it was mostly a process of trial and error. I’ll try to give the best break down I can. (Most of my photos were for my own reference when I was building it, so they kinda suck.)
I started with the base of this face shield. Not sure it was the best choice in the end, but I made it work. There are lots of cheap protective masks out there, so I’d look around.
The face mask I got sat too far away from my face so I ended up only keeping the actual clear acrylic and head band piece and scraping all the black plastic.
I used a hand saw to shape the clear plastic (It was way too big, took some off the top and sides) and attached the clear acrylic directly to the headband with some metal wire. (I had drilled holes where I wanted the clear plastic to join with the headband)
The wire was nice because it had some wiggle, meaning I could lift up the mask a little, which was handy for being able took peek out, or talk more clearly.
To tint it, I used spray adhesive and a sheer purple fabric. It was easy to see out of, but I couldn’t see much in the way of details, unless it was very close up.
I then started with foam sheets making the “metal” around the mask.
Since the acrylic itself isn’t curved at the top or bottom, I tried to make the foam core have the illusion of it looking like that.
Then I masked the acrylic off with tape, spray painted, and then went in with brushes for more details.
The mouth piece was air dry clay over a large button! Just sculpted it by hand.
That’s pretty much it. Sorry it’s not step by step, but I hope the pictures will help you out. The helmet was pretty cheap to make, (Foam sheets are the best!) Just keep checking while you’re making it, with a mirror or photos! Let me know if you have anymore questions!