But I'm getting ahead of myself.
Back to the visor. I finally got the foam shaped right, though it wasn't as rigid as I knew I needed. I found a local shop that sells an awesome translucent purple acrylic sheet, though it was thicker than I had hoped. Got two sheets just in case.
First I tried papier mache to strengthen the foam buck, though the dogs tried to eat it (I got to it in time). That didn't last past the heat gun, unfortunately, and the closest I got to a visor shape was this:
After a while I gave up, ready to spend money to get a company to do it for me. My good friend Zach at Quantum Entanglement Props saved my day though, offering to help me out. Neither of us have a vacuum former, but he had enough experience from his day job to know some tricks we could try. Drove up to him, cooked up the sheet in his grill...
Unfortunately I nicked a couple spots, namely in the back left corner and a piece on the front right cracked. I was running out of time, and if I didn't get this to the customer that day it wouldn't make it in time for the convention. They wanted lights too, so I threw those in as quick as I could.
The biggest complaints, of course, were the crack and the hole, but they also had things to say about the quality. "Wasn't worthy of DragonCon" and that it looked "like a four year old made it" also came up. They complained about the back, the seams, that wouldn't be seen even once. Eventually they demanded their money back, and have since returned it.
So, now I have a Tali helmet made of foam, with a visor that, though it does have those two problems, is passable and replaceable in the future. I will absolutely admit that I could have made it better, but there it is.
If anyone is interested in purchasing it, I am taking offers. Please send me a message through the Contact page, if you wish to talk more regarding this item.