From what I've read in other forums, the visor is cut out of a face sheild that you can find at most hardware stores (check any fourum that has "helmet" in the title for a picture.) I'm currently looking for the best tint to use on it.
I'm actually, as we speak, in the process of finishing up my new helmet (pics to come shortly). I am using a #5 green as well, I think a #3 would be too light. How is everyone else attaching their visor into the helmet?
I drove to a friends house one night and vision was great even with the shade 5. The real treat was driving down my block and seeing a car pull over. Naturally, I slowed down and looked over to give them the classic "Fett nod".
Needless to say, I gave one of them a more than mild shock when he looked through the window.
On my first helmet, I used one of the Ebay visors, it was ok, but a little bit of a pain to make it fit into place. It was also a little too thick to be easily reshaped, basically, it all depends on what helmet it's going into. If I had to do it all over again, I would've used the face shield from the get-go. The face shield is a little thinner, so that it doesn't press into your face (if you have a larger head) and it is more easily molded and pressed into position. You don't have to pay shipping on it, and I got mine cheaper than buying the visor on Ebay ($8 at my local welding supply shop). Just my $.02