I posted this on the RPF but thought I would update here as well:
Update time.
The cracked visor was taken out today!
A fair word of warning.. a few actually..
The visor is VERY brittle. It originally cracked pulling it off of my head form. (used in above photos) it cracked again with slight flexing of the helmet. If you plan on wearing this thing, you absolutely need to replace the visor. Not only did it crack easily but the shards were
sharp! I would not want that breaking anywhere near, or God forbid on, my face.
Second. It is a lot easier to take it out BEFORE you assemble the helmet permanently. I used a dremel and got it about flush to where the visor sat. If there are some gaps between it and the new visor it won't kill me so I'm not too worried.
Third... Slush casting resin will not assemble the helmet permanently.
Used 80 grit sand paper to rough it up and slush cast SC320 into it, and it peeled out like no one's business. I have had silicone molds fight me more than this helmets plastic. However, If it's just for display you should be fine. It didn't come out until I really started handling it.
If anyone is getting ready to tackle this I hope this helps... Don't make my mistakes!!