Okay, so I spoke to Gino about some things in regards to the helmet before SDCC but posting got swept away with me prepping for that con.
The helmet wasn't at SDCC because the gentlemen that owns eFX, Bryan, forgot that box at his house.
The damage that has been done to the ESB helmet over the years will not be replicated nor will there be a Legendary edition that would replicate the helmet in it's current condition. Their past LE sales led them to conclude that the LEs aren't really a viable option for them. Even though I personally feel that Boba collectors are the perfect market for a Legendary release.
Now in regards to the ears, the ears for the actual release helmet will be metal. The ones that appear on the current display piece were just some quick molds that Gino whipped up and sanded down accidentally too far so that the piece could be ready for SDCC 2013.