This is what you'll be getting.
Cap & Back
Trim the excess flashing off the face
When you get the kit, the face will have some excess plastic. Trim the line straight up and down.
Masking tape helps
It's easier to do if you mark off with some tape where your lines should be.
Yes, magnets are involved in every build I do. I use 5 pairs of rare earth magnets for my test fit: 2 on the center of the forehead, a pair each on the side traps, and a pair each at the tubes on the side.
Test fit, other side
The stunt helmets had higher foreheads. Don't know what stunt helmet means? Go to http://www.starwarshelmets.com. Go on, I'll still be here when you are done!
Tools for the face
There are 2 Dremel bits I use: The sanding drum and that small cutting bit to the right of it.
I have a corded and a cordless model. I use the cordless whenever possible, since it's easier to not deal with the power cord.
Closeup of the bits
Cleaned up with the dremel sanding drum
Lens, test fit
Holding the lens in place
This is how they look after the dremel.
Squared up with files
I used a small square file to finish the job.
Face is ready!
Small screw hole
I reassembled, checked for the last time, then drilled a small hole right near the tube.
Into that small hole goes a little #4 screw. This helps keep it from slipping around.
if you look at the helmet from the side, you'll see that the ear is spanning the overlap between front and back. To make it fit better, I sand out a little indent at the back of the ear. This lets it nestle into the indent better.
Square off the cap and back
The cap should come to a nice square corner, right by the back end of the trap.
Test fit, side
The hero style helmets had lower brows. Don't know what hero helmet means? Go to http://www.starwarshelmets.com. Go on, I'll still be here when you are done!
I went stunt with this build
Eye, rough cut
This is what it looks like after cutting out the eye with that cutting bit
Eye, hand cleaned
Once cooled, I pulled off the excess plastic.