Quick Update!
First of all - huge kudos to my friend Colin - he's a Sandtrooper in our squad and is going to be putting together a Boushh for his wife. He's been a great help, and has all the tools/space we need to do this right!
So instead of casting to plastic right away, we wanted to see what we were getting. We used an expanding foam to fill the silicone mold. Good thing we did too. The plaster shell wasn't strong enough and created a bunch of bumps and dents within the helmet.
[ATTACH=full]134426[/ATTACH]
Colin sanded down the foam and then we created a fibreglass jacket that slipped over itself. This gave the silicone mold a lot more stability.
[ATTACH=full]134427[/ATTACH]
So today we started casting! It took me a while to get the right amount of smooth on....I started with small amounts and it was taking forever. But eventually, we got the whole helmet cast.
[ATTACH=full]134428[/ATTACH]
There ended up being a few issues still in the same areas - a few bumps....but we managed to smooth it out with a heat gun and a little elbow grease. The only issue right now is that the back detailing where the lip is on the mold does not line up properly. Colin was mentioning to fix it with bondo...but we'll see.
I still have quite a lot of smooth on left, and should be able to cast another 2 or 3 lids. The ones I don't use I will sell as budget lids.
The armor and missing scope should be in the mail soon from Fangs, who will also be starting on the soft parts for us by the end of the month or so.
Had to do a quick test fit 
[ATTACH=full]134429[/ATTACH]
