Hey, another ToEleven build. Awesome!
AND you plan on using this as a potential plug to mold and cast? And you plan on selling some??? 
If that's really the case, then I wouldn't mind being the first in line for one! lol
I had attempted one before with an old WOF build I did years ago, and I was actually thinking of doing something similar with the RWHv2 for some future projects, but I ran into some sizing issues a while back, and I haven't decided if I'll get back to it. As rewarding as it is, scratchbuilding can sometimes be a chore. But you're plugging right along, and it's looking fantastic already!
Do you know how you plan on tackling the ears? Like using block molds or perhaps just making them a part of your build? Are you thinking of turning these into full-fledged kits or just focusing on helmets?
Either way, I wish you good luck! I'll have to keep an eye on this thread.
P.S. Even though I haven't really messed with sintra myself, perhaps using an organic respirator might help with fumes when heating? As weird as it might be to wear that in the house, you can never be too cautious! 
