I think realistically it's been said a suit cost anywhere $200 upwards. The software is free and if you're doing only a helmet, you may only need 15-20 sheets of 110lb cardstock.
Another option would be print it off regular paper and glue it to a thick bristol board that you can get at the dollar store. My only concern going that way is the paper may eventually unglue from the bristol board, possilbly creating air pockets and problems in the future.
A pack of 250 sheets of 110 lb card stock shouldn't cost more than $15...