"We maintained the exact same visor area from the
first helmet but sculpted an entirely new helmet
around it. The yellow visor part shown was vac
formed for a good solid air tight fit to the final
resin cast helmet."
They vac formed the visor!!! i knew it was possable!!
I don't think anyone ever said that it is, did they? If so, they've been grossly misinformed
Very cool costumes on the link though I've chatted a bit with the sculptor that did those, Dave somebody, he's on a few forums I use. Very talented and helpful chap, makes some amazing batman stuff among other things.
That seems the easiest, vacuum forming isnt cheap anyways. You'll spent 100+ dollars just making a visor.
Also, for a pep one, just paint it gold/silver then get a gold or silver visor and cut it into pieces, cut out the indented areas of the visor, and put the gold/silver visor there, you can see slightly from the sides and the front.
Vacu-forming isn't the problem, gold-tinting what you vacu-form is. If you use regular window-tint you run into two problems: it will get air bubbles due to gas given off by the plastic, and it doesn't conform to a compound curve. I spent the better part of two weeks contacting various companies I found on the internet to see if I could find one that would apply a gold mirror coating to vacuformed plastic, but came up empty... the only hope you would have, and this is a long shot mind you, would be to know someone who works in a shop where they make motorcycle visors, and get them to tint it for you. But, like I said, that's a long shot...