The visor is smoked acrylic that I heated & formed into shape. I left a little bit of a gap at the eye corners to help with venting & didn't seal up everything tight.
The gasket was made by tracing the helmet & making a pattern from that. There is a detailed thread archived here somwhere that goes into the proceedure in full.
Alot of time & effort was spent bringing this helmet to life & I'm pretty sure it will be the last one I paint up. Time to move on to other projects!
No, your eyes do not deceive you. There is a definite curvature of the mandibles. I'll have to dig up the pics that show this detail, but it is definitely there.
Bonus! More pics! I have one more to add in natural light from a recent trooping event. My head isn't straight in the pic (I was fumbling with some keys) but I liked how the colors looked.
Thanks for the compliment. My armor is vacuformed styrene. I think I only made 3 sets of this. One of my next projects will be to tweak the armor & cast it up in fiberglass. Ahhh... the upgrades never end, do they?
@BKBT: I'm not sure, if that was already answered somewhere, but how much does your bucket cost?
I'm pretty disappointed with mine and thinking of getting a new one after Ep III. And as yours is praised as the best available and even seeker-aproved ...