I was thinking this would work great...

[SNate]

So when I was deployed to Iraq, I got a similar ballistic helmet upgrade kit. It was pretty comfortable on an issued military brain bucket, so I was thinking it could be used in a Fett bucket. What do you think? Anyone tried it yet?

Ballistic Helmet Pads - Military Helmet Liners

 

[BGHunter]

I think they would both be good the BLSS looks pretty good and looks prety comfortable.
give it a go

 

[thrax]

Funny, I was working on the same thing for my phase II cone and Asok Jango...here are some links:
TEAM WENDY ZAP™ FOAM PASGT HELMET RETROFIT KIT - Brigade Quartermasters
BLSS Kit Helmet Pads Oregon Aero BLSS Kit Helmet Pads Products Model: Price: $119.99 [] - $119.99 : Full Spectrum Gear, Taking it a step further! | Tactical Military Gear in Petawawa, Ontario

I like the 4-point chin strap harness. i don't like the idea of my helmet coming off easily. I like a costume to be as functional as possible.

Great thinking SNate! I was in the sandbox from 2007-2008

 

[thrax]

BTW, if anyone wants the ACH chin strap (4-point). I can sell them fo $25.00 each shipped US.

 

[SNate]

Don't like chin straps...I may still have a few connections in Cali for these. Possibly free. I will keep you guys updated. If I can get them for free, I will get as many as I can and hand em' out to you guys as well.

BTW in the sandbox:
USMC 2006-2007 and 2008-2009
26 months total in that stinking country! LoL

Edit to add...
These should be fairly easy to fabricate yourself...
Also, I did a search for making molds...can anyone point me to a good tut? I got a zillion hits. Thanks

 

[Fett 4 Real]

I use the pad from my Helo helmet