Guys - thanks for all the nice comments. I really appreciate it. It was a nice project to make, and I'm eventually going to finish my Little Jango helmet too. I've got a little more tweeking and sanding to do on it. I have the mold material at home now just waiting on me to finish it.
I still cannot thank Lee enough for the awesome paint job he did on it. It looks so cool.
I do have some bad news though. When I was cleaning this bucket up I left it in my shop and the heat warped it pretty badly. Well, not to be stopped, I put a metal hoop in the back to make it round again and glued a wire in the front to hold it into place and keep from warping again.
Well, after I got it back from Lee, Will tried it on. Apperantly I must've widened it, which in turn shortened the distance from the front to back. Needless to say, Will can barely wear it 
. He can get it on his head, but he has to keep the chin pushed up so it doesn't smash his nose flat.
As a consolation, my wife bought him one of those Ep III clone trooper costumes to wear this Halloween. There's no way I would have the time to finish his Fett up now that I have to add making a new bucket to list. But one day soon...and hopefully before he gets too big for it
.
ZeroVisibilite - sent you a PM.
GlennP - I did use sintra for the trim around the visor. The ear caps are made from it as well. Why did I use styrene...Well, for one I didn't have to heat it to shape it around the helmet I was using as a base. Cutting and sanding it was easy too. You can see in this pic the sintra parts on the left.
