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I guess I was speaking a little hyperbolically. :lol: My point is that I believe there should be less chamfer when trying to replicate the screen used ESB helmet "Borden" than what is seen on most replicas, including John's here. That's what I meant by the "absolute slightest" chamfer. I'd bet if you backed off on the chamfer on the holes by half or so the holes would look to be the correct size compared to your hero casting. As for the material, first hand accounts of the hero helmet have reported that it is aluminum and I would tend to agree when looking at the way light hits the highlights in photos of the originals.


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