I pulled molds off all the parts including the helmet. I used to make my earlier version,non licenced withthree parts, the licenced version is vac formed in a single pull, the eye lense and "ears" are added, we cut out the pointers and insert a strip behind them whish is an orange and black.
we used to use latex as a mask over the grey but found that dabbing the colour with a foam works well and is faster, we never intended the final item to be screen accurate but a fair representation of the character , as I said, 8 years ago attitudes were somewaht different
I dont know if this was a screen used item,a stunt helmet or a spare, I do know that lots of helmets/costumes were made so if there was a breakage film could continue, if you look in star wars chronicles you will see I think ten sets of vader armour and parts on a table with a couple of guys haming it up
