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Try using thin cardboard or poster board.  Cut out a rough template bigger than you want the

final size of your visor.  Lay it inside the helmet and trim it until you get it to the right size. 

Make sure to leave enough that you'll have some overhanging material all around (except for the bottom).


Also, mark your template so that you know which side is left/right.  The helmets aren't 100% symmetrical.


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