You realize that even if you spend thousands of hours and tons of hard work to make your own helmet from scratch, mold it and sell it, you're still in copyright infringement. Lucas could issue a C&D to anyone who made a helmet or other prop (and has before) for infringing on intellectual copyright. Anyone recall a time when sites like this were in real trouble? We were accused of "giving people the knowledge an means to break intellectual copyright law".
Everything we do is a gray area when it comes to ethics and morals. What's not a gray area is the CoC. I can't count how many times this topic has been discussed before. I'm not saying you have to leave it alone (since there are a lot of new members who haven't joined in this discussion yet) you should just know that feelings have been hurt, people have been flamed, and members have even left over this.