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Vacu-forming is a completely different animal.  Tho, you wouldn't vacu-form the silicon, you can still cast the helmet in silicon and pull a plaster positive from the silicone mold.  I recommend a gypsum/plaster mix as it is a harder cast and less likely to crack under the pressure of vacuum-forming. 


I myself would recommend the fiberglass option over the vacu-forming.  The vacu-form would have to be done in two pieces, which is always a pain to reassemble.  You can do the fiberglass in one piece.  It is much easier and produces a stronger product.

 

Stronger still, and easier to work with.  My personal preference is resin casting.  The very same plastic you get from the site I listed in the previous post (www.smooth-on.com) I use the smooth cast 300.  It is cast in much the same way as the fiberglass, but it has far less fumes, and easier to work with in all respects.  It's less gunky, so it's easier to spread around the cast.  You do have to keep it moving untill it sets tho, or it will pool up and harden.


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