@mulreel you know once i get past 220 it's all by hand. and come to think of it, a small paintbrush might be easier that some guys have been having with their paints not being happy with each other.
@jinto i attach the ear to the helmet with flat head machine screws. i sink two holes into the ear, just deep enough for the head of the screw to go in, then hold it in place with some 5 minute epoxy. then drill matching holes through the helmet and hold it all together with a washer and acorn nuts. and to attach the rf to the stalk, i just drill two tiny holes through the stalk and match them up to the rf and hold it all together with a pair of 5/64" flat head screws. if you would like some pics of any of this to help understand it better just let me know.
oh yeah, update. i got one of the helmets sanded down with 120 grit, and it only took two pads with my mouse sander. only four more to go, then i get to start over with 220! go meeeeee!!!!!!
*edit*
just to let everyone know who all these helmets belong to - one will be a jango with the works for jsames; weathering, padding, visor... the works! one is for asok, his will be a custom mando named vhonte thervo (i don't know who that is, but apparently she's pretty cool, and bill sent me a cd full of reference and the action figure, and after looking at rav bralor i think i've got this one on lock). the third is will be a swap with squirk and be not be weathered, he'll send back the one he got from me originally and get this one instead (look for a finished helmet in the cargo hold from me sometime soon). and the cruzer is for me, it may end up being my main trooping helmet because it's a bit larger than the asok. nothing against bills work, his helmet is descended from a screen used "hero" helmet, so i totally blame ilm for making a small bucket and temura for having a small head! lol