lol... i haven't heard the word "munted" for so long... sorry to hear that the arm got destroyed, things like that always suck... on the upside, having been through what you've already made and doing it again you'll know what works where and what parts to pep first to avoid tricky spots...
i have a rather large melon, and generally find that a scale height of 30cm is fine, leaving plenty of room to fit in padding and electronics. mind you though, i am over 6'2" without shoes so i can get away with larger helmets. i would try to do a basic pep of the cqb first to see if that is the right size for you, maybe even use the full hd version but only pep enough of it to find out if it'll fit first...
it's good to see you working on this helmet again, i would really love to see it as a finished piece, and i know that if your second pep is anywhere as good as your first, this suit is gonna rock
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