Well I am finally almost done with my helmet! There are lots of pictures up on my Flickr page. http://www.flickr.com/photos/8880579@N02/?saved=1
All I have to do is add the little vents on the front of the helmet, and I'll be finito. If anyone was curious, I used paper mache and regular acrylic...
I wouldn't even attempt it with Pepakura if I were you. Why don't you get some really good reference pictures and build it from cardboard and other stuff? You could even use a nerf gun for a base and build around it. Just throwing ideas out there because in Pepakura that would have like 150...
Oh I agree, window tint works great, that's what I used on mine. Unfortunately, I just decided that I didn't like the color, so I'm going to get a better one later.
Where did you "hear" that it was 60 bucks? Might just be your mom not wanting you working with dangerous chemicals (just saying :) ) It is only around $15-$20 per quart, depending on where you get it (those are just the prices I have seen poking around online) so you could potentially do it for...
Personally, I'm going to hot glue mine (because it sets fast) then strengthen it with craft glue. I'm not actually using the motorcycle visor. I'm just using a sheet of polycarbonate. But make sure it is in securely becuase It might flex a bit and slowly pull apart crappy glue.
Link is broke...If you go to Home Depot you can probably tell them what you are doing, and they can figure out what respirator. Also, I don't think resin will give you cancer >< it's just very bad for your lungs.