Nice bucket Keith
just wonderin how you cut the key holes out for one and exactly how do you intend to install your visor.
I'm going to make some metal brackets for the visor, just like the real Fett helmets have.
I cut the keyholes out by drilling lots of holes in the area to be removed, then i used the drill as a kind of cutter by pulling it from one hole to the next, i then used a modeling file to clean the holes up and make them nice and square.
Its going to be an ESB version, i will either try and buy some of the visor brackets, or cut them out of sheet steel, drill the hole for the screw and then bend them into shape.
I will glue them to the inside of the helmet, then apply over them like the ROTJ version.