Duct tape to make the pattern. A little creepy? Yes. But a good first step… if you have a helper to cut you out.

Once cut off, this serves at the pattern
Thin craft foam keeps the helmet light and comfortable. I covered the seams to add detail and make it look more… uhh… seamless.
Leather- and Latex-look spandex.. I put the zippers in the shoulders for (relatively) easy getting in and out.
The finished product. Ready for San Diego Comic-Con!

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