It's always a good idea to pep sitting in front of a computer with pep designer open displaying the file you're working on. This way, you have easy access to part locations, and what ever else may pop up. Also, the helmet Macattack64 posted a picture of is the MK VI, not the MK IV. I started looking at the MK 4 helmet (from halo wars).
And while typing I just realized I made it 365mm and not 265... SO there will be very thick foam or Ill just sell it and make another one fit for me because my head is small compared to that.
Looks like the brim is slightly hanging towards one side, there are a few dents here and there and the ridges on top are pretty crazy.
The dents are not so dramatic, you can easily fix those later. But the other two things would be hard or impossible to fix with Bondo, so unless you can push everything into place with support struts, you maybe shouldn't harden this one unless you absolutely want to practice.
I am still sanding it down, just thought I should update because I have'n't in a while. Is there any tip on how to remove all the dust from it? I have been using a hair dryer. XD