Got some of the ear pieces made. Cut out the visor to see if Will could see through a smaller hole. I think he can, so I'll be able to get the visor closer to the right look. Sanded the second coat of Bondo down.
Front and back view

Nice perspective view...

The black at the top of the cheeks will get some pieces of sintra added and <sigh> more bondo...
All that's really left to fab now is the RF, stalk, and ear cap...and there's only 9 days left till Christmas!