i just built one, but unfortunately i didn't do many progress pics.
i can describe what i did, if that's at all helpful.
i took the pattern pieces from the template and traced them ono a sheet of plastic.
cut out the plastic, leaving me the funny "flat pattern" shaped piece.
score it along the various lines where it folds and bend. the plastic snapped into all of the little separate pieces.
i then taped the pieces together and hot glued them.
geat job Brian looks great
Start here http://www.thedentedhelmet.com/showthread.php?t=10800
This is the one that I made http://www.thedentedhelmet.com/showthread.php?t=24680
One very important thing to remember, you are going to print out something that is flat and has no thickness. You will need to take into account the thickness of the plastic, cardboard, or whatever when you trim it out. Make sense?