I'm building a Daft Punk helmet (Thomas) for my son for Halloween and have it done, minus the tinted visor. I'm having a heck of a time finding visor material at a local store. Anyone have any hints on where this stuff usually lives?
I would maybe check a motorcycle shop for tinted wind screens. A plastics shop or glass repair place may have a thin tinted lexan or polycarbonate that would work as well. I would try to find a tinted material, as trying to tint flexible clear plastic with car tint is frustrating.
If you go to the welding shop and buy the replacement visors, you'll save time and headaches. They are already curved, slightly flexible, thinner, and I cut mine with scissors instead of melting the heck out of it with a dremel. I messed around with tinted 1/8" plexi. Way too much trouble, and not dark enough.
Motorcycle helmet visors should work. Flexible enough for fitting into a helmet without breaking. You also have a wide selection of colors, sizes, etc. I've got a smoke lens and a silver lens I'll be choosing between