My primary costume reference was the Sideshow Collectible’s 12” figure because I like the lighter brown tunic, but it will not be 100% accurate to this version because there are details I like from the screen used costume that I'll incorporate.
I'll start out this thread by posting a few pics of my modified mask/helmet that I finally finished last night.
I used a latex Plo Koon mask and carefully layered it on the inside with expanding liquid "rigid" foam. It is now hard just like a resin helmet, but I left the neck areas unlayered so I can still put it on. The mask itself was not symetrical in the ears so it's a little more noticable after applying the rigid foam. I added a little weathering to give it a more realistic look.
I removed the ear pieces that connected to the breathing mask and made them removable. I also filled them with expanding liquid "soft" foam to give them some solidness. After a little trimming to one side because it was much longer than the other, I repainted them and added some metal accents to help give the mask a more realistic appearance. I couldn't find any detailed pics of these metal "connections"of the screen used costume, so I replicated the pieces as they were seen on the latex mask.
I would like to say "thank you" to Dark-side for inviting me to be a part of this Italian pro forum.
Enjoy,
Cruzer
...but not when it's made by an Italian Jango with long hair! 
