Ok, I have some questions to answer!
Sarim Thiri: I will indeed be making copies, as previously mentioned in the thread. This cardboard/fiberglass/bondo mockup will be wearable for myself, but I'm actually making it to be my first helmet mold and will be molding it before I paint it. I'm going to make a rubber mold of it and then do resin copies. I'm looking at using rotocast or something like that for simplicity and for experimentation with materials. The nature of the helmet would prevent easy access to key areas for fiberglassing, but it could be done after the fact I suppose. I want to make the casting process as easy on my end as possible, as I do intend to sell copies in small quantities. The plan is to sell copies as kits, with the helmet pulled right out of the mold with the edges cleaned up, and the horns cast in resin as separate pieces.
Montatora Viroria: I haven't decided what scheme to color it. I want to keep it "accurate" to the source materials, but I do have some options. There is the lighter olive drab and yellow/gold that looks very nice, but then there is the darker black version which just looks plain menacing. I think I'd like to do the black version though, but I'd do extensive weathering on it, like the Boba helmets.
987654321a: I have extensive experience in working with Bondo, and that's actually one of the best qualities of it - the cure time is pretty fast. However, because of the extensive surface area covered, I wanted to give it as much time as it needed, especially since we were going through a humid/rainy period. I also really just didn't want to rush too much with it.
Here's my final progress for the evening. I got the visor cut out and sanded smoothish. I also carved out those horizontal lines at the sides of the visor area. The lineart has those lines coming directly out of the visor, but I decided to give a little 1/4" space between the visor and the line. The line was carved out with the router bit on my dremel turned on it's side.