Thanks, Count D! I'm still enjoying doing helmets. I don't see myself getting burned out. . . but I have an optometrist's appointments later this month (not a joke) to see how my poor old eyes are doing. :facepalm
UPDATE #2: Sep 8th (DAY 13)
I just wanted to show my ear attachment method. I talked to Chad and described a couple of different ways to put the ears on. He chose the bolt method.
What I do is hold the ears against the helmet and determine a couple of good spots to fit some bolts. I pick 2 spots per ear, and 1 thru the center of the upper RF ear cap. This one acts as a pivot for the RF stalk. Chad said he wasn't planning to install a servo, so it won't interfere with any "internals" but still allow the RF to pivot up and down.
I use a little bullet-shaped grinding bit on my Dremel, and carve out a couple of "scoops" on the back of each ear piece.
Then I'll use JB Weld to epoxy these small machine screws into each ear. I make sure the head of each bolt will actually be just slightly below the surface, so all that sticks out are the threaded portions.
Once the JB Weld cures, those suckers are in there for the long haul.
I'll then drill corresponding holes in the sides of the helmet, making sure to make them just slightly large enough to have a little bit of play so the ears will line up correctly.
And yes, if my brain were working correctly, I would have done this at the beginning, before painting.
But at this point, I just wiped off a little resin dust, and everything's good to go.
So close to being done now!!