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I think you will see what I mean when you get a fiberglass helmet.  As is mentioned above, the thickness of the fiberglass isn't consistent so the inside edge, the edge that the visor sits on, isn't consistent no matter how you cut out the visor area.  If you want a smooth edge on the inside you will HAVE to bondo it somewhat.  No big deal except for the fact that the visor is so difficult to get to from the inside.  I HIGHLY recommend getting a set of large and small files.  This made work SO much easier.  if I had to rely on sandpaper alone I would have killed myself long ago.  Files rule because they are fast working on large areas and they are good for straight level lines.  A dremel is good too but it is very easy to screw things up with a dremel but you have a great deal of control over a file.


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