Start off with a full-faced motorcycle helmet. Find the smallest size you can (this one was a kids XS). Don’t worry if it doesn’t fit, you’ll be gutting all the insides.
saw the chin part of the helmet off. Remove all of the padding and styrofoam on the inside. Remove all the of the screws on the outside.
Attach a stencil of Samus’ chin part of the helmet.
For the earpieces, use a pair of safety muffs. Gut the padding and remove the head piece.
It’ll attach to the side of the helmet like above.
Transpose the chin stencil onto 1/8″ PVC sheet.
Attach the PVC chin piece to the helmet. Heat as necessary to get the desired bend.
Using spackle or bondo, fill in the holes left from the removed screws. Fill in any gaps between the newly installed chin piece and the helmet. Using a power sander, sand the ear pieces until they fit flush to the sides of the helmet.
Above shows bondo being applied (before sanding it smooth).
Sanding the entire surface of the helmet until it is ALL uniform and smooth. Rinse out dust and dry with a cloth. Apply masking tape for the black lines on the helmet.
Prime the entire helmet.
Paint the entire helmet.
Cut a piece of clear acrylic for the visor portion.
Attach it to the insides of the helmet as shown above.
Remove the tape and color on the black lines on the helmet.
Using then vacuum tubing, attach it from the front of the earpieces to the inside of the chin. Attach a trapezoid shape of PVC to fill in the gap on the chin piece.
Using a green tinted visor, place on the back of the acrylic.