Done!
I've had all the parts in my possession for a few weeks now but finding the time to squirrel myself away in my shop has been hard to come by.
First up was to wrap the rest of the parts with carbon fiber, which went just as smoothly as the tester piece went. After that I gave it the slightest hint of normal wear and tear; scuffs with sand paper along edges and a light blackwash to add a touch of grime. Then two coats of clear matte top coat for a bit of protection.
Then came cutting some frosted plexi to diffuse the light from the LEDs. Once those were installed, it was on to assembling the electronics. I learned that I've got a lot to learn when it comes to electronics (the picture below can attest to the mess I can make when trying something for the first time). There is a lot of wiring jammed in here: 7 LEDs with their own resistors, a 3 AAA battery case, a 5v fan, a small switch and almost 13 feet of wire. And there's still room for my head too! One sage piece of advice I can pass on: test early and test often! I mis-wired the LEDs first and then after I corrected that I had a bit of a puzzle when only the front of the helmet would turn on with the switch while the rear was constantly on. I figured out my problem when I found a piece of wire on the floor that belonged in the helmet. A few minutes later and the whole thing worked like a charm!
Once I had the wiring harness sorted and mostly installed, I reinstalled the visor and added some padding. Neatly tucked away the nest of wires and promptly wore the thing around the house for a while
This has been a very fun process; lots of new skills, problem solving and making a good mess. I'm looking forward to moving on to other projects: Halo 4 armor? A suit of ME3 armor to complement this helmet? Weapon peps? So many choices...
Thanks again to the 405th community as a whole for providing inspiration and know-how and to anyone who has taken the time to check out my build!