Random Progress 1

 Tools:

1) Electric hot knife - great for cutting foam
2) X-acto mini saw
3) X-acto thin saw - great for cutting curves on foam

Muzzle placement:

using toothpicks to place the muzzle in 3D space. Trying to get the angle and distance correctly. Then to fabricate the piece to connect it to the rest of the helmet.

Visor Edge:

I'm using a piece of sewing thread to mark my line. This is for the upper edge of the visor opening.

There. That should be plenty of space for vision. It shouldn't be a problem anymore.

I didn't like the thinness of the walls. So, I doubled up. I really don't like the jaggies of the cuts. I'll have to cover them up later.

Muzzle It

Muzzle:

Here I'm using some thin foam-core boards to build up my shape for the muzzle.

This area is pretty complex in shape. Has so many angles coming from all sides. No right angles anywhere. So many curves. I have to measure everything twice before cutting once. Always a good carpenter's rule.

 Muzzle box finished.