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Could likely just dab a line of bondo over the edges that have the lifting that creates the seam and then square them up with a flat sanding block. Keeps the ears seperate and as long as the helmet's ear surface is also flat should mate up perfect.

I've done that tons of times to get sharper corners on things. Typically not the best for durability, but the inside corners of the ears are a pretty low impact area.

[QUOTE="Grimstuff, post: 528044, member: 8643"] Could likely just dab a line of bondo over the edges that have the lifting that creates the seam and then square them up with a flat sanding block. Keeps the ears seperate and as long as the helmet's ear surface is also flat should mate up perfect. I've done that tons of times to get sharper corners on things. Typically not the best for durability, but the inside corners of the ears are a pretty low impact area. [/QUOTE]

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