@ carpathiavh: The test visor I used is just a sheet of transparency film, about as thick as a sheet of paper. The actual plastic I'm going to use comes from a toy box. It's thick to act as a visor, but thin enought to bend without breaking. If you have a really thick piece of plastic, you can use a heat gun to help you bend it. Hope this helps some.
@ sarge079: I plan on making the correct folds, and the securing it in with hot glue. Because I'm cutting the plastic from the pep file design, it should fit pretty good. Just trying to find how to dye it.
update: I've finished painting the helmet, and I'll try to have pics posted sometime this week.